Joint compound, wall assembly, and methods and products related thereto

ABSTRACT

Disclosed are aspects of board finishing systems. For example, in various aspects, disclosed are joint compound compositions, wall assemblies, methods of treating walls, and products related to any of the foregoing, including reinforcement trim, e.g., for protecting corners where boards meet, fasteners, and tape. The joint compound preferably is a drying type composition with reduced shrinkage property, and includes binder and hollow spheres, resulting in an ultra lightweight formulation in some embodiments. The joint compound composition can be applied in a one-coat treatment in preferred embodiments. Other aspects of board finishing system accommodate such a one-coat treatment to thusly allow a user to manipulate the compound closer to the plane of board as compared with conventional formulations. Joint tape and reinforcement trim can include non-swelling synthetic paper facing material in some embodiments.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part patent application ofcopending U.S. patent application Ser. No. 13/842,342, filed Mar. 15,2013, which claims the benefit of U.S. Provisional Patent ApplicationNo. 61/705,551, filed Sep. 25, 2012. All of the preceding patentapplications are incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

In building construction, different types of claddings are used aspanels for forming interior and exterior wall and ceiling surfaces. Forsimplicity, as used herein, it will be understood that the term “wall”also encompasses ceilings. Typically, the claddings are in the form ofboards (also referred to as panels) affixed to framing members such asin balloon framing arrangements known in the art. Examples of claddingsinclude gypsum board faced with paper, fibrous mats (e.g., fiberglass),and the like. These and other types of boards are typically cut toappropriate dimensions and then fastened to framing members, e.g., withscrews, nails, or the like to form wall sections formed from multipleboards.

Such wall sections are normally finished to provide aestheticallypleasing, uniform, and protected surfaces. For example, two side-by-sideboards disposed in the same plane will form a joint seam between them onvertical walls and horizontal ceilings. To finish the seam, jointreinforcement tape is embedded in the seam, along with a layer of jointcompound under the tape, and multiple coats of joint compound appliedover the tape. Some boards meet at an angle such as when forming acorner. Reinforcement bead can be utilized to hide the corner seam andto protect the corner. Reinforcement bead can be directly attached tothe board using fasteners, or a layer of joint compound is applied underthe trim to adhere the reinforcement bead to the board. The installedreinforcement is then concealed with multiple layers of joint compoundapplied over the trim. Fasteners used to affix the board to framingmembers must also be concealed with multiple layers of joint compoundapplied over them. After the various joint compound applications aredried, the resulting wall surfaces can be sanded and painted to form thedesired uniform and aesthetically pleasing appearance.

The level of finishing as described above can vary. For example, withrespect to gypsum wallboard, six (6) levels of gypsum board finish areunderstood in the art, ranging from zero (no treatment at all) to levelfive (the highest level of finish), as set forth in Gypsum Associationdocument GA-214 and American Society for Testing and Materials (“ASTM”)C840. The level of finish generally corresponds with the number ofapplications of joint compound to seams, trims, and fasteners. Levelsthree, four, and five are typically used for occupied spaces withinbuildings. For single family homes, level 4 is the most common levelthat is implemented. Level five is less frequently used and usuallyrequires application of a skim coat of joint compound across the entirewall surface.

Conventional approaches for finishing wall assemblies as described abovehave not been fully satisfactory. The materials conventionally used tofinish wall assemblies create significant inefficiencies in the processand also require an advanced level of skill to use effectively. Forexample, existing joint compounds require three separate coats to beapplied to fasteners as well as multiple coats applied to flat seamsbetween boards in the same plane and to corner seams. Each coat mustseparately dry which introduces significant downtime in the constructionprocess, particularly since the other construction trades ordinarilycannot work inside the building while the wall finishing occurs. Eachlayer of joint compound can require about a day to dry, and it typicallycan take about a week to install the gypsum board and finish the flatjoints, fasteners, and corner trims for a typical new construction of ahome of 2,400 square feet of living space (corresponding to about 10,000square feet of board).

In addition, the need for applying multiple coats of joint compoundrequires that the user manipulate the joint compound significantly abovethe plane of the board. To allow the board to appear flat to the nakedeye (even though it is not), significant skill and workmanship isrequired to achieve the proper visual appearance when the user isfunctioning above the plane of the board. The additional layers of jointcompound must be feathered out wider and wider from the seam in agraduated manner to make the seam appear aesthetically flat. If the useris not significantly skilled, the visual appearance will not besatisfactory.

It will be appreciated that this background description has been createdby the inventors to aid the reader and is neither to be taken as areference to prior art nor as an indication that any of the indicatedproblems were themselves appreciated in the art. While the describedprinciples can, in some regards and embodiments, alleviate the problemsinherent in other systems, it will be appreciated that the scope of theprotected innovation is defined by the attached claims and not by theability of the claimed invention to solve any specific problem notedherein.

BRIEF SUMMARY OF THE INVENTION

In one aspect, the invention provides a drying-type joint compoundcomposition. The joint composition comprises, consists, or consistsessentially of binder selected from acrylic acid polymers, acrylic acidcopolymers, alkyds, polyurethanes, polyesters, epoxies, and combinationsthereof. The composition also comprises a plurality of hollow spheres.The spheres desirably have an average isostatic crush strength of atleast about 100 psi as measured according to ASTM D3102-78.

In another aspect, the invention provides a joint compound compositionconsisting essentially of (a) latex emulsion binder in an amount fromabout 3% to about 90% by weight of the wet composition; (b) a pluralityof hollow spheres having an average isostatic crush strength of at leastabout 100 psi as measured according to ASTM D3102-78, wherein thespheres are present in an amount from about 5% to about 25% by weight ofthe wet composition; (c) nonionic surfactant in an amount from about0.001% to about 5% by weight of the wet composition; and (d) humectantin an amount from about 0.001% to about 3% by weight of the wetcomposition; and, optionally, (e) defoamer in an amount from about 0.05%to about 5% by weight of the wet composition; (f) rheological modifierin an amount from about 0.1% to about 5% by weight of the wetcomposition; (g) biocide, in an amount from about 0.1% to about 1.5% byweight of the wet composition; (h) bulk filler, such as calciumcarbonate or limestone in an amount from about 1% to about 40% by weightof the wet composition; and (i) delaminated clay, such as kaolin clay,in an amount from about 0.1% to about 5% by weight of the wetcomposition.

In another aspect, the invention provides a wall assembly comprising,consisting of, or consisting essentially of two adjacent boards, joinedby a seam. Only one-coat of the joint compound is applied over the seamto provide a uniform aesthetic appearance. The joint compoundcomposition comprises binder selected from acrylic acid polymers,acrylic acid copolymers, alkyds, polyurethanes, polyesters, epoxies, andcombinations thereof. The composition also comprises a plurality ofhollow spheres. The spheres desirably have an average isostatic crushstrength of at least about 100 psi as measured according to ASTMD3102-78. The wall assembly further comprises dimensionally stable,non-swelling flat joint tape embedded in the seam.

In another aspect, the invention provides a method of treating awallboard assembly of two adjacent boards joined by a seam. The methodcomprises, consists of, or consists essentially of applying joint tapeand one coat of the joint compound composition to the seam. The jointcompound composition comprises binder selected from acrylic acidpolymers, acrylic acid copolymers, alkyds, polyurethanes, polyesters,epoxies, and combinations thereof. The composition also comprises aplurality of hollow spheres. The spheres desirably have an averageisostatic crush strength of at least about 100 psi as measured accordingto ASTM D3102-78. The method further comprises drying the composition.

In another aspect, the invention provides a reinforcement trim forprotecting a seam of two adjacent boards having opposing face and backsurfaces, the faces being disposed with respect to each other at anangle between the board faces. The trim comprises, consists of, orconsists essentially of paper face comprising non-swelling syntheticpaper facing material and a backing. For example, the facing materialcan be laminated to a sturdy, rust-resistant material designed to impartsuperior long term corner angle joint reinforcement that exceeds theminimum performance requirements established in ASTM C1047-10a (StandardSpecification for Accessories for Gypsum Wallboard and Gypsum VeneerBase) for crack resistance and chipping, resulting in corner vertex thatremains straight during normal building movement and/or displacement anddaily wear-and-tear. In some embodiments, the backing comprises metalsuch as galvanized steel and/or other backing material having theaforesaid desired properties, including, for example, composite laminatestructure, layered paper, thermoplastic, thermoset, carbon fiber,polyester, polycarbonate, spun polyolefin, natural or synthetic fiber,woven material, and the like.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a perspective view of a wall assembly.

FIGS. 2A-2B are alternative sectional views taken substantially from theline 2-2 of FIG. 1, wherein FIG. 2A illustrates a conventional taper forcomparative purposes, while FIG. 2B illustrates a shallower taper inaccordance with embodiments of the invention.

FIGS. 3A-3B are alternative sectional views of a finished joint of twowallboards with tapered edges abutting, wherein FIG. 3A illustrates ajoint with conventional wide feathering of joint compound forcomparative purposes, while FIG. 3B illustrates narrower feathering ofjoint compound, closer to the plane of the board, in accordance withembodiments of the invention.

FIGS. 3C-3D are alternative sectional views of a finished joint of twowallboards with square (i.e., non tapered) edges abutting, wherein FIG.3C illustrates a conventional joint with wide feathering of jointcompound for comparative purposes, while FIG. 3D illustrates narrowerfeathering of joint compound, closer to the plane of the board, inaccordance with embodiments of the invention.

FIGS. 4A and 4B are exploded perspective views depicting reinforcementtrim to be applied to a corner formed from two wallboards, wherein FIG.4A shows an outside corner with angle (x), while FIG. 4B shows an insidecorner with angle (y).

FIG. 5 illustrates two adjoining boards affixed to a framing skeleton,wherein the V-shaped cut away shows the presence of adhesive on framingmembers in accordance with embodiments of the invention.

FIGS. 6-7 illustrate installations of wall assemblies, where FIG. 7illustrates a finished room installation after painting, and FIG. 8illustrates taped joints prior to depositing joint compound.

FIG. 8 depicts corner reinforcement trims in accordance with embodimentsof the invention.

FIG. 9 depicts corner reinforcement trim being affixed to an insidecorner with a pressure adhesive in accordance with embodiments of theinvention.

FIGS. 10-11 depict seating reinforcement trip into corners with a rollerdevice in accordance with embodiments of the invention.

FIG. 12 depicts corner reinforcement trims in accordance withembodiments of the invention.

FIG. 13 depicts wall assemblies showing corner reinforcement trimsinstalled on inside and outside corners in accordance with embodimentsof the invention.

FIG. 14 depicts a reinforcement trim for an inside corner with one coatof joint compound in accordance with embodiments of the invention.

FIG. 15 depicts a sanded one-coat finish both for a joint in the machine(horizontal, as shown) direction and for a butt joint (vertical, asshown) in accordance with embodiments of the invention.

FIG. 16 depicts wall assembly installation with joint treatment applied.

FIG. 17 depicts a treated-wall assembly with a V cut to show framingmember with adhesive and one coat of joint compound illustrating narrowfeathering in accordance with embodiments of the invention.

FIG. 18 depicts a conventional joint treatment system with joint tapeembedded in joint compound with two additional joint compoundapplications over the tape requiring a wide feathering of the jointcompound for comparison purposes.

FIGS. 19-21 illustrate the progression of a flexural strength test forsample 2A of Example 2 for comparison purposes.

FIGS. 22-24 illustrate the progression of a flexural strength test forsample 2B of Example 2 for comparison purposes.

FIGS. 25-27 illustrate the progression of a flexural strength test forsample 2C of Example 2 in accordance with embodiments of the invention.

FIGS. 28-29 depict the flexural strength for sample 2C of Example 2 inaccordance with embodiments of the invention.

FIG. 30 is a box plot chart displaying the tension displacement when thefirst crack was observed and was measured in inches (Y-axis) and variousjoint compounds in accordance with embodiments of the invention andcomparative examples (X-axis).

FIG. 31 is a box plot chart displaying the load (lbs) when the firstcrack was observed and was measured in pounds (lbs) (Y-axis) and variousjoint compounds in accordance with embodiments of the invention andcomparative examples (X-axis).

FIG. 32 is a box plot chart displaying the shear displacement when thefirst crack was observed and was measured in inches (Y-axis) and variousjoint compounds in accordance with embodiments of the invention andcomparative examples (X-axis).

FIG. 33 is a box plot chart displaying the shear peak displacement whenthe first crack was observed and was measured in inches (Y-axis) andvarious joint compounds in accordance with embodiments of the inventionand comparative examples (X-axis).

FIG. 34 is a box plot chart displaying the shear displacement ratio(i.e., a ratio of peak displacement at joint system failure todisplacement at first crack) (Y-axis) and various joint compounds inaccordance with embodiments of the invention and comparative examples(X-axis).

FIG. 35A illustrates a modified ASTM E72 racking assembly system with an8′×8′ (about 2.4 m×about 2.4 m) assembly prepared from 2″×4″ wood studs(about 5 cm×about 10 cm). The wood studs are not shown.

FIG. 35B illustrates the modified ASTM E72 racking assembly system ofFIG. 35A configured with the 2″×4″ wood studs placed 16 inches (about0.4 m) apart.

FIG. 35C illustrates the modified ASTM E72 racking assembly system ofFIG. 35B, where the bottom was rigidly fixed to the structure, and aforce was applied at the top left corner by a hydraulic ram programmedto run a sinusoidal waveform with varying amplitudes.

FIGS. 36A to 36C show the drying profile of the joint compounds of thepresent invention compared with the conventional joint compounds for athick coat, i.e., about 3/16 inches (about 0.5 cm), in which the percentof water evaporated (Y-axis) was plotted against the incremental dryingtimes represented along the X-axis). FIG. 36A shows the drying profilesin a moderate environment, e.g., 75° F. and 50% relative humidity. FIG.36B shows the drying profiles in a hot and dry environment, e.g., 95° F.and 10% relative humidity. FIG. 36C shows the drying profiles in a coldand humid environment, e.g., 40° F. and 80% relative humidity.

FIGS. 37A to 37C show the drying profile of the joint compounds of thepresent invention compared with the conventional joint compounds for athin coat, i.e., about 1/16 inches (about 0.2 cm), in which the percentof water evaporated (Y-axis) was plotted against the incremental dryingtimes represented along the X-axis). FIG. 37A shows the drying profilesin a moderate environment, e.g., 75° F. and 50% relative humidity. FIG.37B shows the drying profiles in a hot and dry environment, e.g., 95° F.and 10% relative humidity. FIG. 37C shows the drying profiles in a coldand humid environment, e.g., 40° F. and 80% relative humidity.

DETAILED DESCRIPTION OF THE INVENTION

In various embodiments, the present invention relates to joint compoundcompositions, board finishing systems, wall assemblies, methods oftreating walls, and products related to any of the foregoing, includingreinforcement trim, e.g., for protecting corners where boards meet,fastener, and tape. Various aspects of the invention advantageouslyimpart considerable efficiencies in the finishing of wall assembliescomprising cladding, such as gypsum drywall, mat-faced board (e.g.,having fiberglass facing), and the like. For example, the presentinvention allows for wall finishing to take place with significantlyfewer steps required for any given desired finish level, e.g., a level 4finish in accordance with Gypsum Association document GA-214 and/or ASTMC840 (“level 4”). As a result, wall finishing can occur more rapidlywith less downtime. In addition, wall finishing in accordance withaspects of the invention requires less skill by users during claddinginstallation.

One aspect of the invention is predicated, at least in part, on thesurprising and unexpected discovery of joint compound composition thatexhibits low shrinkage. As a result, the joint compound advantageouslycan be applied in fewer coats than conventional joint compounds. In someembodiments, only one coat of joint compound is used over fasteners,joint tape, or reinforcement trims. However, if desired, more than onecoat (e.g., two or three coats) may be applied depending on the level offinish desired. For example, conventional systems suffer fromsignificant shrinkage, such as, for example, exceeding 15%, e.g., about18% or greater. Embodiments of the invention provide considerably lessshrinkage. Embodiments of joint compound also exhibit desirableflexibility properties and can be sanded readily and, desirably, do notcrack.

Because the joint compound composition can be applied in fewer coats,advantageously, a user can manipulate the joint compound closer to theplane of the board. Conventionally, in multi-coat (e.g., 3 coats ormore) systems, the user must broadly feather the joint compound across awide radius from the seam to provide a visual illusion of a flatsurface. Significant skill is required for the user to achieve suchappearance when the joint compound thickness elevates significantlyabove the plane of board and board seams. By using a one-coat jointcompound in accordance with embodiments of the invention, a user willnot need to feather the joint compound as widely, and less skill isnecessary to achieve a flat visual appearance. In some embodiments,board is specially designed to have a smaller taper than conventionalboard or no taper at all (i.e., squared edge) in the machine directionedges as described herein.

In other aspects, the invention provides for a special non-swellablematerial that can be used in joint tape as well as for a face layer inreinforcement trim composite used to conceal and protect wall cornerswhere two boards meet at an angle (e.g., an “inside” corner or “outside”corner as understood in the art). The trim can also include a backing(e.g., comprising metal or other material) to provide rigidity andsupport.

Adhesive can be used in various aspects of the invention. In someembodiments, the adhesive is an aqueous quick-drying adhesive such as anaqueous wall covering adhesive (e.g., such as those marketed by RomanAdhesives), an aqueous bonding agent (e.g., such as those marketed byUnited States Gypsum Company), or an aqueous latex emulsion glue (e.g.,such as those marketing by OSI). For example, such adhesive can beapplied to framing members to minimize the number of fasteners used tohang board. Adhesive can also be used to facilitate application of jointtape and reinforcement trim in accordance with embodiments of theinvention.

A fastener, in accordance with embodiments of the invention, can be usedto accommodate a single coat of joint compound. For example, thefastener can include a concave head design to create a dimpled effectalthough other fasteners are possible, including staples or otherdrywall screws. One or more of these various aspects can be combined ina board finishing system in accordance with embodiments of theinvention.

Reference is now made to the figures to depict advantageous illustrativeembodiments of the invention. FIG. 1 depicts a wall assembly 100comprising three boards 110, 112, and 114 which are affixed to framingmembers 116 by way of fasteners 118. Any suitable cladding can be usedas the board. For example, gypsum board normally comprises a corecomprising an interlocking matrix of crystalline gypsum with desiredadditives such as polyphosphate, starch, dispersant, accelerator,retarder, etc., between two cover sheets in a sandwich structure. Thecore can optionally comprise a skim coat disposed on a core surfacefacing one or both cover sheets. The invention is not limited withrespect to the techniques for manufacturing the cladding, and the boardcan be made in any suitable manner as known in the art.

The framing members 116 are desirably provided with adhesive 120 topromote adhesion to the boards 110, 112, and 114 and to allow the use offewer fasteners 118 than are used in conventional systems. Sincefasteners need to be covered by joint compound, reducing the number offasteners is thereby advantageous in terms of efficiency, ease, andquality of installation.

Board edges are generally identified as being in the machine directionor cross direction based on how the board is made on the manufacturingline. Edges along the machine direction are normally the longer edgesand are usually wrapped with cover sheet (e.g., made of paper) duringboard manufacture in which a cementitious slurry is deposited on amoving cover sheet (e.g., on a conveyor) to initially form a long,continuous ribbon of board precursor, which is eventually cut in thecross direction to desired dimensions as known in the art (e.g., 4′×8′;4′×10′; 4′×12′; etc., although different widths and lengths arepossible, including 36 inch wide board, or 54 inch wide board). Forexample, board 110 has machine direction edges 122 and 124 andcross-machine edges 126 and 128. Similarly, board 112 has machinedirection edges 130 and 132 and cross-machine edges 134 and 136, whileboard 114 has machine direction edges 138 and 140 and cross-machineedges 142 and 144. As discussed in FIGS. 2A and 2B below, the machineedges are typically tapered. The cut cross-machine edges are normallynot tapered.

Two boards can meet in various configurations to form a seam, oftenreferred to as a joint. Since machine edges are tapered while crossmachine joints are not tapered, the nature of the joints will varydepending on which edges of the boards meet. When a machine directionedge of one board meets a machine direction board of another board, amachine direction joint is formed where two tapers meet to form arecess. When a cross direction edge of one board meets a cross directionedge of another board, a butt joint, without tapers, is formed. As seenin FIG. 1, boards 110 and 112 join to form a machine direction joint146, and boards 112 and 114 join to form a butt joint 148.

To illustrate the tapered edges in the machine direction of board,reference is made to FIGS. 2A and 2B, which are sectional views,illustrating alternate depths for the taper from board 110. A board core210 has a top surface 212 and bottom surface 214. Normally a top coversheet facing top surface 212 wraps around machine edge 124 and meets abottom paper which faces bottom surface 214. It will be understood thatthe sandwich structure of board 110 with core 210 between two coversheets is typically formed upside down such that the top surface 212 ison the bottom. If desired, during manufacture, the board can be flippedprior to entry into a kiln for drying excess water. The core 210 canoptionally comprise skim coats as known in the art, e.g., on top surface212 and/or bottom surface 214.

FIG. 2A shows a conventional taper 216 with a significant depth (D) forthereby defining a recess 218. Since conventional joint compound issusceptible to significant shrinkage, the depth (D) is large toaccommodate receiving copious amounts of joint compound in recess 218for embedding joint tape therein to compensate for the shrinkage upondrying. The taper with substantial depth (D) is further designed toassist the user by reducing the height above the plane of the board inwhich additional coats of joint compound are manipulated in conventionalsystems. For example, conventional tapers can define a recess depth ofabout 0.08 inch at the deepest point. Even with such conventional depth(D) on the taper, the user must still undesirably manipulate jointcompound considerably high above the plane of the board.

FIG. 2B illustrates an alternate taper in accordance with embodiments ofthe invention. A board core 220 has a top surface 222 and bottom surface224. Normally a top cover sheet facing top surface 222 wraps aroundmachine edge 124 and meets a bottom paper which faces bottom surface224. The core 220 can optionally comprise skim coats as known in theart, e.g., on top surface 222 and/or bottom surface 224. Duringmanufacture, the board can be formed upside down initially and flippedas desired as described above.

As seen in FIG. 2B, the taper 226 has a depth (D) that is considerablysmaller than what is conventional, as shown in FIG. 2A. Such a taper 226defines a recess 228 which is smaller than conventional and isparticularly useful with low shrinkage joint compound in accordance withembodiments of the invention. In some embodiments, no taper is providedeven in the machine direction such that the board has a square edge(i.e., D=zero). Thus, since no taper is possible in various embodiments,the taper 226 can define a recess depth at the deepest point from about0 inch to about 0.05 inch, e.g., from about 0 inch to about 0.04 inch, 0inch to about 0.03 inch, 0 inch to about 0.02 inch, 0 inch to about0.015 inch, 0.005 inch to about 0.05 inch, 0.005 inch to about 0.04inch, 0.005 inch to about 0.03 inch, 0.005 inch to about 0.02 inch,0.005 inch to about 0.015 inch, 0.01 inch to about 0.05 inch, 0.01 inchto about 0.04 inch, 0.01 inch to about 0.03 inch, 0.01 inch to about0.02 inch, etc.

FIGS. 3A-3D are sectional views, illustrating different arrangements forlevel 4 finishing of a joint between two wallboards. Particularly, FIGS.3A and 3B illustrate a joint between two tapered boards (e.g., boardsadjoining along machine direction) where FIG. 3A illustrates aconventional system with multiple coats of joint compound forcomparative purposes, and FIG. 3B illustrates one coat of joint compoundin accordance with embodiments of the invention. FIGS. 3C and 3Dillustrate a joint where two square edges meet without taper (e.g., in abutt joint or machine direction joint without taper). In this respect,FIG. 3C illustrates a conventional multi-coat system for comparativepurposes while FIG. 3D illustrates application of one coat of jointcompound in accordance with embodiments of the invention. While boardcores are shown, it will be understood that cover sheets can be appliedas described above.

In FIG. 3A, a board assembly 300 comprises a first board 302 having acore 304 and a tapered edge 306. A second board 308 comprises a core 310and tapered edge 312. Tapered edges 306 and 312 meet to form a taperedjoint 314. Tape 316 is applied over joint 314. Conventional systemsrequire a joint compound layer 318 for embedding tape 316 over joint314. Conventional dispensing tools can be used to dispense tape 316 andjoint compound layer 318 together. After allowing joint compound layer318 to dry, a joint compound second layer 320 is applied over the tape316. Then, after the second layer 320 dries, a joint compound thirdlayer 322 is applied over second layer 320. The three layers of jointcompound 318, 320, and 322 are required in conventional systems tocompensate for the significant shrinkage resulting from conventionaljoint compound chemistry.

FIG. 3B depicts a one-coat system in accordance with illustrativeembodiments of the invention. A board assembly 324 comprises a firstboard 326 having a core 328 and tapered edge 330. A second board 332comprises a core 334 and tapered edge 336. It will be understood thatthe tapered edges 330 and 336 both can have a smaller slope thanconventional tapered edges 306 and 312 depicted in FIG. 3A and asdescribed in relation to FIG. 2B above. Tapered edges 306 and 312 meetto form a tapered joint 338. Tape 340 can be applied over joint 338 byway of adhesive 342. The adhesive 342 can be in any suitable arrangementrelative to tape 340, but in some embodiments the adhesive is on abottom surface of the tape 340 and is optionally protected by adhesiveliner. The adhesive can be any suitable adhesive, e.g., applied bypressure (such as by hand, knife, roller or other device). Unlike theconventional arrangement illustrated in FIG. 3A, only one joint compoundlayer 344 is required as shown in FIG. 3B.

FIGS. 3C-3D illustrate alternate embodiments for a square edged joint(i.e., without taper) as might be used in a butt joint or square edgedmachine direction joint. In FIG. 3C, a board assembly 346 comprises afirst board 348 having a core 350 and a straight edge 352. A secondboard 354 comprises a core 356 and straight edge 358. Straight edges 352and 358 meet to form a square edged joint 360. Tape 362 is applied overjoint 360. Conventional systems require a joint compound layer 364 forembedding tape 362 over joint 360. As noted above, conventionaldispensing tools can be used to dispense tape 362 and joint compoundlayer 364 together. After allowing joint compound layer 364 to dry, ajoint compound second layer 366 is applied over the tape 362. Then,after the second layer 366 dries, a joint compound third layer 368 isapplied over second layer 366. The three layers of joint compound 318,320, and 322 compensate for the significant shrinkage in conventionaljoint compounds.

FIG. 3D depicts a one-coat system for square joint in accordance withillustrative embodiments of the invention. A board assembly 370comprises a first board 372 having a core 374 and straight edge 376. Asecond board 378 comprises a core 380 and straight edge 382. Straightedges 376 and 382 meet to form a square edge joint 384. Tape 386 can beapplied over joint 384 by way of adhesive 388. The adhesive 388 can bein any suitable arrangement relative to tape 386, but in someembodiments the adhesive is on a bottom surface of the tape 386 and isoptionally protected by adhesive liner. The adhesive can be any suitableadhesive, e.g., applied by pressure. Unlike the conventional arrangementillustrated in FIG. 3C, only one joint compound layer 390 is required asshown in FIG. 3D.

Conventional systems, as shown in FIGS. 3A and 3C, require the threelayers of joint compound (318, 320, and 322) and (364, 366 and 368)which results in the user having to manipulate the joint compoundsignificantly above the plane (P) of the board at a height (H) as shown.The height (H) is even more extreme in squared edged embodiments (as aretypical with respect to butt joints) such as shown in FIG. 3C, inasmuchas there is no taper below the plane (P) of the board to receive somecompound. For example, the height (H) of conventional systems can be, atleast about 0.1 inch, e.g., at least about 0.125 inch or higher. Theuser must have significant skill to manipulate the compound to appearflat to the naked eye when functioning that high above the plane of theboard. Typically, the joint compound is progressively feathered furtherand further away from the joint 314 or 360, respectively. Because of thesignificant height (H), the feathering is at a substantial width (W) asshown to give the visual appearance of a flat covered joint. Forexample, the width (W) of conventional embodiments as shown in FIGS. 3Aand 3C can be at least about 30 inches, e.g., about 36 inches or more inconventional systems.

The inventive embodiments illustrated in FIGS. 3B and 3D advantageouslyresult in smaller height (H) and width (W) for depositing and featheringthe joint compound as compared with the (H) and (W) for thecorresponding conventional arrangements set forth in FIGS. 3A and 3C,respectively. This is because the user is not required to function ashigh above the plane (P) of the board and thusly does not need tofeather the compound layer 344 and 390, respectively, as far wide as inthe conventional systems of FIGS. 3A and 3C. For example, the height (H)in some inventive embodiments can be under 0.1 inch and, preferably, theheight (H) is under 0.7 inch, such as about 0.0625 inch or less or about0.05 inch or less (e.g., 0.02 inch to about 0.1 inch, 0.02 inch to about0.07 inch, 0.02 inch to about 0.0625 inch, about 0.02 inch to about 0.05inch, about 0.05 inch to about 0.1 inch, about 0.05 inch to about 0.07inch, about 0.05 inch to about 0.0625 inch, etc.). Similarly, the width(W) of embodiments of FIGS. 3B and 3D for feathering the joint compound344 and 390, respectively, can be considerably smaller than the width(W) of corresponding conventional systems (e.g., as shown in FIGS. 3Aand 3C). For example, the smaller width (W) of advantageous embodimentsof the invention can be about 20 inches or smaller, such as about 18inches or smaller, 15 inches or smaller, 12 inches or smaller (e.g.,about 5 inches to about 20 inches, about 5 inches to about 15 inches,about 5 inches to about 12 inches, about 5 inches to about 10 inches,etc.).

FIGS. 4A and 4B depict illustrative embodiments for treating seams whereboards meet at an angle, e.g., to form a wall corner. Corner anglereinforcement trim can define and reinforce the corner angles, providecontinuity between intersecting gypsum board planes, and conceal gypsumpanel corner seams when covered with compound. For example, toillustrate an outside corner, FIG. 4A depicts a wall assembly 400comprising a first board 410 having a face 412. A second board 420 hasface 422. The boards 410 and 420 meet at an angle to form a corner seam424 adjacent to a face edge 426 of board 410. The angle (x) is definedby the intersection of the faces 412 and 422 in what is understood inthe art as an outside angle forming an outside corner. The outside anglecan be any suitable angle depending on the wall configuration anddimensions as understood in the art. Typically, the angle (x) is areflex angle as shown in FIG. 4A, i.e., an angle exceeding 180°,although smaller angles are possible in more unique corners. Forexample, in some embodiments, the angle (x) can be in a range of, e.g.,from about 180° to about 300°, including angles near 270°, such as fromabout 230° to about 330°, from about 250° to about 310°, about 260° toabout 300°, about 260° to about 280°, about 265° to about 275°, or about268° to about 272°.

As seen in exploded view of FIG. 4A, a reinforcement trim 428 is appliedover the outside corner seam 424 and face edge 426 to cover and protectthe edge 426 and seam 424. Trim 428 comprises a trim face 430 withreinforcement backing 432, which has a width that does not extend as faras the width of the trim face 430 in some embodiments. Adhesive 434 isused to apply the trim 428 over the outside corner seam 424 and faceedge 426. Joint compound, including one coat joint compound inaccordance with embodiments of the invention, is applied over the trimto hide the trim and seam. After it is applied and dried, the compoundcan be sanded and painted to provide a uniform aesthetic appearance.

To illustrate an inside corner, FIG. 4B depicts a wall assembly 450comprising a first board 452 having a face 454. A second board 460 hasface 462. The boards 452 and 460 meet at an angle to form a corner seam464. The angle (y) is defined by the intersection of the faces 454 and462 in what is understood in the art as an inside angle forming aninside corner. The inside angle can be any suitable angle depending onthe wall configuration and dimensions as understood in the art.Typically, the angle (y) is an angle below 180°, although larger anglesare possible in more unique corners. For example, in some embodiments,the angle (y) can be in a range of e.g., about 30° to about 180° or fromabout 45° to about 135°, including angles near 90°, such as from about60° to about 120°, about 70° to about 110°, about 80° to about 100°,about 85° to about 95°, or about 88° to about 92°.

As seen in exploded view of FIG. 4B, a reinforcement trim 466 is appliedover the inside corner seam 464 to cover and protect the seam 464. Trim466 comprises a trim face 468 with reinforcement backing 470, which hasa width that does not extend as far as the width of the trim face 468 insome embodiments. Adhesive 472 is used to apply the trim 466 over theseam 464. Joint compound, including one coat joint compound inaccordance with embodiments of the invention, is applied over the trimto hide the trim and seam. After it is applied and dried, the compoundcan be sanded and painted to provide a uniform aesthetic appearance.

The trim face 430 or 468 desirably comprises non-swelling paper (naturalor synthetic) in some embodiments. The non-swelling paper isparticularly desirable in one coat systems since less compound will goover the paper and disguise any unwanted swelling that might lead tobulging or other unsightly results. For example, in some embodiments,the face 430 or 468 has a dimensional stability of less than about 0.4%machine direction (MD) expansion and less than about 2.5% cross machinedirection (CD) expansion (e.g., less than about 0.3% MD expansion, andless than about 1.5% CD expansion, such as less than about 0.2% MDexpansion, and less than about 1% CD expansion after 30 minute immersionin water, ASTM C474-05, Section 12. It will be understood thatembodiments that pass testing relative to ASTM C474-05 can also exceedthe minimum performance specifications established in ASTM C475/C475M-12Standard Specification for Joint Compound and Joint Tape for FinishingGypsum Board.

In some embodiments, the face 430 or 468 has a thickness from about 0.01inches (≈0.0254 cm) to about 0.125 inches (≈0.318 cm), such as fromabout 0.05 inches (≈0.127 cm) to about 0.0625 (≈159 cm). It will beunderstood that the joint tape can be composed of the same materials,characteristics, and properties as the reinforcement trim face.

The backing 432 or 470 for the reinforcement trim 428 or 466 cancomprise any suitable material that provides strength to the trimcomposite. The backing material is useful to reduce, control, oreliminate seam cracking in the wall angles when new construction framingshifts and minor wall displacement occurs. The backing material also, inconjunction with the facing material, serves the function of forming atrue and straight angle line along the vertex where two walls join orintersect at an angle. For example, the trim backing 432 or 470 cancomprise a composite laminated structure, layered paper (synthetic ornatural), thermoplastic, thermoset, natural or synthetic fiber, carbonfiber, polyester, polycarbonate, fiberglass, non-woven natural orsynthetic materials, woven natural or synthetic materials, spunpolyolefin, or metals such as steel, e.g., electro-galvanized and/or hotdipped galvanized, zinc phosphate treated and/or dried in place chromatesealer, and/or other treated or coated metal and the like. For example,in one illustrative embodiment, the backing 432 or 470 is formed ofgalvanized steel. The trim backing 432 or 470 desirably has any suitablethickness, e.g., a thickness of at least about 0.010, e.g., about 0.012inches (≈0.030 cm) to about 0.0625 inches (≈0.159 cm), such as fromabout 0.012 inches to about 0.030 inches (≈0.0762 cm). In someembodiments of backing material, such as when galvanized steel is used,the backing typically imparts a Rockwell hardness scale B from about 45to about 85, such as from about 55 to about 65, when measured accordingto ASTM E18-03.

Preparation of trims is illustrated in embodiments with non-swellablepaper face with galvanized steel backing. The trims are prepared byrunning flat steel (on a spool) through a series of progressive dies andthe facing material and metal backing are introduced just after the lastset of dies. The facing and backing can be hot-melt glued together insome embodiments. Other techniques for forming reinforcement trimsformed from a variety of materials will be apparent to one of skill inthe art.

FIGS. 5-18 are photographic images depicting various illustrativeembodiments of the invention. In particular, FIG. 5 shows a cut away ofboard to reveal panel adhesive applied to framing. FIG. 6 depicts a roominstallation after painting. As seen in FIG. 6, a finished wallinstallation in accordance with embodiments of the invention can achievea level 4 drywall finish with one coat of joint compound and without theneed for multiple coats of joint compound as in conventional systems. Inaddition, FIG. 7 depicts joint tape that has been adhesively appliedover the seams of gypsum panels before the gypsum panels are treatedwith joint compound.

With respect to inside and outside corner installation, FIG. 8 depictsoutside corner trims that are fabricated with non-swellable paper facewith metallic backing. Meanwhile, FIG. 9 depicts an inside cornerreinforcement trim with non-swellable paper face and metal backing beinghand pressed into place. FIGS. 10-11 depict application of trimembodiments of the invention using a roller. FIG. 12 depicts outsidecorner trim pieces. FIG. 13 depicts a room installation with all insideand outside corner trims and flat joint tape installed. FIG. 14 depictsflat joint tape on the inside corner trim on the upper left-hand cornerof the image. The lower right-hand corner of the image depicts one coatof joint compound applied to provide a level 4 drywall finish inaccordance with embodiments of the invention.

FIG. 15 depicts flat joint tape with one coat of joint compound appliedon the left side of the image. It can be seen that a butt joint (crossmachine joint) without taper has been concealed with application of onecoat of joint compound and then sanding. The right side of the imagedepicts the finished painted look. FIG. 16 depicts a room installationwith joint treatment installed while FIG. 17 depicts a finished wallcut-away to reveal panel adhesive applied to framing with tape and onecoat of joint treatment. Furthermore, FIG. 18 depicts a gypsum boardwith conventional level 4 drywall finish with only a 12 inch widefeathering in accordance with embodiments of the invention.

In these and other embodiments, joint compound composition in accordancewith the present invention comprising (a) binder, (b) hollow spheres(sometimes referred to as bubbles) having an average isostatic crushstrength of at least about 100 psi (e.g., at least about 250 psi) asmeasured according to ASTM D 3102-78, and optionally other ingredients.Preferably, the joint compound composition exhibits low shrinkage. Forexample, in some embodiments, the joint compound composition exhibits ashrinkage of about 10% or less by volume, e.g., about 7% or less, suchas about 5% or less, about 2% or less, about 1% or less, about 0.1% orless, or about zero (no shrinkage) as measured by ASTM C474-05, Section6.

The joint compound can have any suitable density, but preferably is anultra lightweight composition having a density of about 10 lb/gal orless, such as about 8 lb/gal or less. For example, in some embodiments,the joint compound has a density from about 2 lb/gal (≈240 kg/m³) toabout 8 lb/gal (≈960 kg/m³) (preferably from about 2 lb/gal to about 6lb/gal (≈720 kg/m³), more preferably about 3 lb/gal (≈360 kg/m³) toabout 4 lb/gal (≈480 kg/m³)).

Generally, the composition is a drying type joint compound, wherein thecompound hardens by evaporation of water. Thus, in some embodiments, thejoint compound composition is substantially free of setting-typematerials such as calcined gypsum, cement, or other hydraulicallysetting materials. Furthermore, in some embodiments, the joint compoundcomposition can desirably be substantially free of raw materials such asbulk filler, clays, starch, or mica; including such examples as calciumcarbonate, expanded perlite, calcium magnesium carbonate, limestone,calcium sulfate dihydrate, a gelling clay such as attapulgite clay, adelaminated clay, such as kaolin clay, talcs, and diatomaceous earth.Furthermore, the joint compound composition can desirably besubstantially free of any combination of the aforementioned rawmaterials.

As used herein, “substantially free” of such setting minerals, bulkfiller, clays, starch, mica, or a combination thereof means that thejoint compound composition contains either (i) 0 wt. % based on theweight of the composition, or no such setting minerals, bulk filler,clays, starch, mica, or a combination thereof, or (ii) an ineffective or(iii) an immaterial amount of such setting minerals, bulk filler, clays,starch, mica, or a combination thereof. An example of an ineffectiveamount is an amount below the threshold amount to achieve the intendedpurpose of using such setting minerals, bulk filler, clays, starch,mica, or a combination thereof as one of ordinary skill in the art willappreciate. An immaterial amount may be, e.g., below about 5 wt. %, suchas below about 2 wt. %, below about 1 wt. %, below about 0.5 wt. %,below about 0.2 wt. %, below about 0.1 wt. %, or below about 0.01 wt. %as one of ordinary skill in the art will appreciate. However, if desiredin alternative embodiments, such ingredients can be included in thejoint compound composition.

In alternative embodiments, bulk filler (e.g., calcium carbonate orlimestone) or delaminated clay, such as kaolin clay may be present.These raw materials can be added, in some embodiments, to tailor thejoint compound for the subjective feel desired by the end user duringthe application process. These raw materials, as used herein, do nototherwise change the physical properties of the joint compound. In suchembodiments, up to about 40 wt. % of bulk filler, such as calciumcarbonate or limestone, can be included. If included, in someembodiments, the bulk filler can be present, for example, in an amountof up to about 35 wt. %, up to about 30 wt. %, up to about 25 wt. %, upto about 20 wt. %, up to about 15 wt. %, up to about 10 wt. %, up toabout 5 wt. %, or up to about 1 wt. % added based on the weight of thewet composition. Each of the aforementioned endpoints can have a lowerlimit, e.g., ranging from 1 wt. %, 5 wt. %, 10 wt. %, 15 wt. %, 20 wt.%, 25 wt. %, 30 wt. %, or 35 wt. %, as numerically appropriate.

For example, in various embodiments, the bulk filler can be present fromabout 1 wt. % to about 40 wt. %, e.g., from about 1 wt. % to about 30wt. %, from about 1 wt. % to about 25 wt. %, from about 1 wt. % to about20 wt. %, from about 1 wt. % to about 15 wt. %, from about 1 wt. % toabout 10 wt. %, from about 5 wt. % to about 30 wt. %, from about 5 wt. %to about 25 wt. %, from about 5 wt. % to about 20 wt. %, from about 5wt. % to about 15 wt. %, from about 5 wt. % to about 10 wt. %, fromabout 10 wt. % to about 30 wt. %, from about 10 wt. % to about 25 wt. %,from about 10 wt. % to about 20 wt. %, from about 15 wt. % to about 30wt. %, from about 15 wt. % to about 25 wt. %, or from about 20 wt. % toabout 30 wt. %.

If included, delaminated clay, such as kaolin clay, may be present insome embodiments, for example, in an amount up to about 5 wt. %, up toabout 4.5 wt. %, up to about 4 wt. %, up to about 3.5 wt. %, up to about3 wt. %, up to about 2.5 wt. %, up to about 2 wt. %, up to about 1.5 wt.%, up to about 1 wt. %, up to about 0.5 wt. %, or up to about 0.1 wt. %added based on the weight of the wet composition. Each of theaforementioned endpoints can have a lower limit, e.g., ranging from 0.1wt. %, 0.5 wt. %, 1 wt. %, 1.5 wt. %, 2 wt. %, 2.5 wt %, 3 wt. %, 3.5wt. %, 4 wt. %, or 4.5 wt. %, as numerically appropriate.

For example, in various embodiments, delaminated clay, such as kaolinclay, can be present from about 0.1 wt. % to about 5 wt. %, e.g., fromabout 0.1 wt. % to about 4 wt. %, from about 0.1 wt. % to about 3 wt. %,from about 0.1 wt. % to about 2 wt %, from about 0.1 wt. % to about 1wt. %, from about 0.1 wt. % to about 0.5 wt. %, from about 0.5 wt. % toabout 5 wt. %, from about 0.5 wt. % to about 4 wt. %, from about 0.5 wt.% to about 3 wt. %, from about 0.5 wt. % to about 2 wt. %, from about0.5 wt. % to about 1 wt. %, from about 1 wt. % to about 5 wt. %, fromabout 1 wt. % to about 4 wt. %, from about 1 wt. % to about 3 wt. %,from about 1 wt. % to about 2 wt. %, from about 2 wt. % to about 5 wt.%, from about 2 wt. % to about 4 wt. %, from about 2 wt % to about 3 wt.%, from about 3 wt. % to about 5 wt. %, from about 3 wt. % to about 4wt. %, or from about 4 wt. % to about 5 wt. %.

Any suitable binder can be used to achieve desired joint compound inaccordance with aspects of the invention. Desired binders hold particlesin composition together and form a film. In some embodiments, the binderis selected from acrylic acid polymers, acrylic acid copolymers, alkyds,polyurethanes, polyesters, epoxies, and combinations thereof. The binderin some embodiments has a glass transition temperature (Tg) from about32° F. (≈0° C.) to about 70° F. (≈21° C.), e.g., about 32° F. to about66° F. (≈18° C.), such as from about 40° F. (≈5° C.) to about 60° F.(≈15° C.), e.g., about 55° F. (≈13° C.). In some embodiments, the binderhas a minimum film forming temperature (MMFT) from about 32° F. to about90° F. (≈32° C.), e.g., from about 32° F. to about 86° F. (≈30° C.),such as from about 40° F. (≈5° C.) to about 60° F. (≈15° C.), e.g.,about 52° F. (≈11° C.).

In some embodiments, the binder generally can be any suitablefilm-forming resin (or combinations thereof) capable of forming a solidfilm and binding solid materials to the surface to which the jointcompound composition is applied. For example, the binder can be anacrylic acid polymer and/or acrylic acid copolymer in some embodiments.The binder is in the form of an aqueous emulsion in some embodiments,with suitable latex emulsion media including, but not limited to,acrylics, such as, for example, vinyl acrylics and styrenated acrylics.In some embodiments, suitable binder materials include acrylic latex,vinyl-acrylic, vinyl acetate, polyurethane, and/or combinations thereof.

Useful latex emulsion media include polyacrylate ester polymers marketedunder the RHOPLEX® trade names (Rohm & Haas), acrylic polymers, vinylacrylic polymers, for example, vinyl acetate-butyl acrylate copolymers,styrene acrylic polymers, and vinyl acetate polymers marketed under theUCAR™ and NEOCAR™ trade names (The Dow Chemical Company, Michigan) suchas UCAR™ 367; emulsion polymers products marketed under the VINREZ®trade name (Halltech, Inc., Ontario); vinyl acrylic polymers marketedunder the Plioway® trade name (Eliokem, Ohio); acrylic, vinyl acrylic,and styrene acrylic latex polymers marketed under the AQUAMAC™ tradename (Resolution Specialty Materials, LLC, Illinois); and vinyl acrylicresin marketed under the trade name VINREZ® 663 V15 (Halltech, Inc.,Ontario), which has a glass temperature of about 18° C. Another vinylacrylic copolymer binder is marketed under product identification no.HP-31-406 (Halltech, Inc., Ontario), and has a glass temperature ofabout 0° C.

Suitable functionalized acrylics, alkyds, polyurethanes, polyesters, andepoxies can be obtained from a number of commercial sources. Usefulacrylics are sold under the ACRYLOID™ trade name (Rohm & Haas, Co.,Pennsylvania); useful epoxy resins are sold under the EPON™ trade name(Resolution Specialty Materials, LLC, Illinois); useful polyester resinsare sold under the CYPLEX® trade name (Cytec Industries, New Jersey);and useful vinyl resins are sold under the UCAR™ trade name (The DowChemical Company, Michigan).

The binder can be included in the joint compound composition in anysuitable amount. For example, the binder can be included in an amountfrom about 5 wt. % to about 100 wt. % by weight (on a solids basis) ofthe wet composition, such as from about 20 wt. % to about 80 wt. %, fromabout 30 wt. % to about 70 wt. %, from about 40 wt. % to about 60 wt. %,etc.

The hollow spheres contain self contained air bound by a solid barrier.Since the air is contained within a solid shell, the air does notcoalesce such that, overall, the air can be distributed throughout thecompound and maintain a substantially uniform density. The hollowspheres facilitate a lower density but desirably have good strengthproperties, such that the hollow spheres impart crush resistance, suchthat the dried joint compound, after application, is substantiallynon-friable, in some embodiments, unlike conventional joint compound,which is friable and brittle.

The spheres in some embodiments facilitate an ultra lightweight jointcompound, which results in desired properties and creates less strain ona user in lifting compound in pails, etc. during a work day. The spherescan have any suitable density, such as a density from about 0.0015lb/in³ to about 0.04 lb/in³, e.g., from about 0.0018 lb/in³ (≈0.05g/cm³) to about 0.036 lb/in³ (≈1 g/cm³), such as from about 0.0036lb/in³ (≈0.1 g/cm³) to about 0.0253 lb/in³ (≈0.7 g/cm³). With respect tostrength, for example, the spheres can have an average isostatic crushstrength of at least about 50 psi (≈340 kPa) as measured according toASTM D 3102-78, such as an isostatic crush strength of at least about100 psi (≈690 kPa). For example, the isostatic strength of the spherescan be from about 50 psi to about 50,000 psi (≈344,740 kPa), from about50 psi to about 25,000 psi (≈172,000 kPa), from about 50 psi to about10,000 psi, from about 50 psi to about 5,000 psi (≈34,000 kPa), fromabout 50 psi to about 1,000 psi, from about 50 psi to about 500 psi(≈3,450 kPa), from about 100 psi to about 50,000 psi, from about 100 psito about 25,000 psi, from about 100 psi to about 10,000 psi, from about100 psi to about 5,000 psi, from about 100 psi to about 1,000 psi, fromabout 100 psi to about 500 psi, from about 250 psi (≈1,720 kPa) to about50,000 psi, from about 250 psi to about 25,000 psi, from about 250 psito about 10,000 psi, from about 250 psi to about 5,000 psi, from about250 psi to about 1,000 psi, from about 250 psi to about 500 psi, fromabout 500 psi to about 50,000 psi, from about 500 psi to about 25,000psi, from about 500 psi to about 10,000 psi, from about 500 psi to about5,000 psi, from about 500 psi to about 1,000 psi, from about 1,000 psito about 50,000 psi, from about 1,000 psi to about 25,000 psi, fromabout 1,000 psi to about 10,000 psi, from about 1,000 psi to about 5,000psi, from about 2,500 psi (≈17200 kPa) to about 50,000 psi, from about2,500 psi to about 25,000 psi, from about 2,500 psi to about 10,000 psi,from about 2,500 psi to about 5,000 psi, etc.

Examples of types of spheres in accordance with embodiments of theinvention include lime boro-silicate, polystyrene, ceramic,recycled-glass, expanded glass, and lightweight polyolefin beads, and/orany other chemical form of plastic. For example, in some embodiments,spheres for use in the joint compound include but are not limited tosoda lime boro-silicate glass bubbles (e.g., as marketed under theScotchlite™ (3M) trade name), multi-cellular hollow glass microspheres(e.g., as marketed under the Omega-Bubbles™ (Omega Minerals) tradename), expandable polymeric microspheres (e.g., as marketed under theDUALITE® (Henkel) trade name), polyolefin micro beads and polystyrenemicrospheres (e.g., as marketed under the Spex•Lite® (Schabel PolymerTechnology, LLC) trade name), expanded glass spheres (e.g., as marketedunder the Poraver® North America trade name), and combinations thereof.As illustrative embodiments, suitable spheres can comprise Scotchlite™(3M) K1 and/or K15.

The spheres can have any suitable diameter and can be provided in anysuitable concentration. It will be understood that the term spheres isknown in the art and does not imply a perfectly geometric sphere,inasmuch as the spheres can have irregular shapes. Thus, the diameter asused herein refers to the diameter of the smallest geometric sphere thatencompasses the actual sphere. In some embodiments, the spheres can havea diameter from about 10 microns to about 100 microns, such as fromabout 40 microns to about 80 microns, or from about 50 microns to about70 microns. With respect to amounts, in some embodiments, the spheresare present in an amount from about 2% to about 50% by weight of the wetcomposition, such as, for example, from about 5% to about 35%, fromabout 7% to about 25%, or from about 10% to about 20%.

In some embodiments, the joint compound composition, optionally, alsoincludes surfactant. Desirably, the surfactant can facilitatestabilizing binder so the binder does not flocculate. Surfactant alsodesirably can provide a wetting or dispersing action. In this respect,when dry raw materials are added to water, the dry materials can competefor water and form unwanted agglomerations. Thus, in some embodiments,the surfactant is included to increase the ease of mixing whenincorporating dry materials in liquid and further assists in pumpingjoint compound from fill stations and into pails during manufacture. Thesurfactant is also beneficial during use, when applying the jointcompound, e.g., with dispensing tools known in the art.

For example, in some embodiments, the surfactant can be a nonionicsurfactant having a hydrophilic-lipophilic balance (HLB) from about 3 toabout 20, such as from about 4 to about 15 or from about 5 to about 10.It will be understood that surfactants with HLB values below 9 aregenerally considered to be lipophilic, those with values between 11 and20 are generally considered to be hydrophilic, and those with valuesbetween 9 and 11 are generally considered to be intermediate. Suitablenon-ionic surfactants having an HLB value below about 9 include, but arenot limited to, octylphenol ethoxylates and nonylphenol ethoxylates,including non-ionic surfactants having HLB values below about 9 marketedunder the TRITON™ and TERGITOL™ trade names (The Dow Chemical Company,Michigan). Suitable non-ionic surfactants having a HLB value greaterthan about 11 include octylphenol ethoxylates and nonylphenolethoxylates which have more ethylene oxide units than the non-ionicsurfactants having a HLB value below about 9. Useful surfactants havingHLB values greater than about 11 are also marketed under the TRITON™trade name (The Dow Chemical Company, Michigan). Other surfactants mayalso be used provided that the HLB value for the (blend of)surfactant(s) is as previously described for joint compound compositionsand combinations thereof. If included, the nonionic surfactant can bepresent in any suitable amount, such as from about 0.001% to about 15%by weight of the wet composition, such as from about 0.001% to about10%, from about 0.001% to about 5%, or from about 0.01% to about 0.5%.

One or more defoamer, such as, for example, petroleum distillate or thelike, as known in the art, is optionally included in some embodiments ofthe joint compound composition. If included, the defoamer can be presentin an amount from about 0.01% to about 15% by weight of the wetcomposition, such as from about 0.05% to about 5%, or from about 0.3% toabout 1%.

Humectant is optionally included in some embodiments. For example,humectants can be used to help keep the joint compound wetter byfacilitating retention of moisture and can also aid with use ofmechanical dispensing tools. In particular, one or more humectants isincluded in embodiments of aqueous joint compound composition in orderto slow the drying of the joint compound composition and provide a moreconsistent finish. Humectants can also advantageously provide freezethaw tolerance and/or stability in the joint compound composition. Anysuitable humectants can be included, such as, for example, sorbitolderivatives, polyhydric alcohols, including but not limited to glycolssuch as ethylene glycol, diethylene glycol (DEG), triethylene glycol,propylene glycol, di-propylene glycol, and/or tri-propylene glycol, orany combination thereof. If included, the humectants can be included inan amount from about 0.001% to about 15% by weight of the wetcomposition, such as from about 0.001% to about 10%, from about 0.01% toabout 5%, or from about 0.001% to about 3%.

Optionally, the joint compound composition comprises a rheologicalmodifier in some embodiments. If included, the rheological modifier isgenerally provided to enhance certain rheological properties such as theflow, viscosity, application properties, and other performanceattributes associated with joint compounds. For example, in someembodiments, rheological modifiers are often added to provide thecoating compositions with desired viscosity values as described herein,e.g., using C.W. Brabender visco-corder equipment for measuring theviscosity of the joint compound composition.

Suitable rheological modifiers for optional use in the joint compoundcomposition include, but are not limited to, cellulosic and associativethickeners, including but limited to, hydrophobically modifiedethoxylated urethanes (HEUR), hydrophobically modified alkali-swellableemulsions (HASE), and styrene-maleic anhydride terpolymers (SMAT),and/or combinations thereof. Exemplary cellulosic rheological modifiersinclude, but are not limited to, cellulose ethers such as hydroxyethylcellulose (HEC), ethylhydroxyethyl cellulose (EHEC), methylhydroxyethylcellulose (MHEC), carboxymethyl cellulose (CMC), hydroxypropylmethylcellulose (HPMC), and/or other cellulose ethers having a molecularweight between about 1000 and 500,000 daltons, e.g., alkyl hydroxypropylcellulose ethers, hydroxypropyl methyl celluloses, as well as xanthangums, sodium alginates and other salts of alginic acid, carrageenans,gum arabic (mixed salts of arabic acid), gum karaya (an acetylatedpolysaccharide), gum tragacanth (a complex mixture of acidicpolysaccharides), gum ghatti (the calcium and magnesium salt of acomplex polysaccharide), guar gum (a straight chain galactomannan) andits derivatives, locust bean gum (a branched galactomannan), tamarindgum, psyllium seed gum, quince seed gum, larch gum, pectin and itsderivatives, dextrans, and hydroxypropylcelluloses, or any combinationthereof.

If included, the rheological modifier can be included in any suitableamount, e.g., to achieve a desired viscosity as will be appreciated byone of ordinary skill in the art. For example, in some embodiments, therheological modifier is included in an amount from about 0.01% to about15%, by weight of the wet composition, such as from about 0.01% to about10%, from about 0.1% to about 5%, from about 0.1% to about 3%, fromabout 0.1% to about 2%, or from about 0.1% to about 1%. The jointcompound typically comprises from about 0.01 wt. % to about 10 wt. %,about 0.1 wt. % to about 5.0 wt. %, and/or about 0.10 wt. % to about 3.0wt. % of the cellulosic thickener. The alkyl group of useful alkylhydroxypropyl celluloses may contain up to 9 carbon atoms, but usuallythe alkyl group contains from one to three atoms. Hydroxypropyl methylcelluloses having an average of about two hydroxypropyl and/ormethoxypropyl groups per anhydroglucose unit are often used. Theviscosity of an aqueous solution containing about 2 wt. % of a suitablealkyl hydroxypropyl cellulose ether at 20° C. is about 60,000centipoises (cps) to about 90,000 cps as measured with an Ubbelohde tubecapillary viscometer. Alternatively, similar measurements can be madewith a Brookfield rotational viscometer at a speed between about 2.5 rpmand 5 rpm. In one refinement, the initially solid-colored coatingcomposition contains about 0.25 wt. % of an alkyl hydroxypropylcellulose ether. Of course, other types of cellulosic thickeners mayalso be used, and a greater quantity may be needed if a lower viscositythickener is used (or vice versa). Exemplary alkyl hydroxypropylcellulose ethers are marketed under the Methocel® trade name (The DowChemical Company, Michigan).

Suitable associative thickeners for optional use in the joint compoundcompositions include hydrophobically modified ethoxylated urethanes(HEUR), hydrophobically modified alkali-swellable emulsions (HASE), andstyrene-maleic anhydride terpolymers (SMAT). HEUR thickeners (alsogenerally known as polyurethane or PUR associative thickeners) can beincluded in aqueous, latex-based joint compound and other yield stressfluid/solid like compositions. Acidic acrylate copolymers (cross-linked)of ethyl acrylate and methacrylic acid, and acrylic terpolymers(cross-linked) of ethyl acrylate, methacrylic acid, and nonionicurethane surfactant monomer may also optionally be used as associativethickeners. When one or more suitable associative thickeners are used,the thickening reaction is caused in part by either association betweenthe associative thickener and at least one other particle of the jointcompound composition (e.g., a pigment particle or resin particle) oranother associative thickener molecule. In various embodiments, ifincluded, the joint compound composition can comprise from about 0.01wt. % to about 10 wt. %, about 0.1 wt. % to about 5.0 wt. %, and/orabout 0.1 wt. % to about 3 wt. % of the associative thickener. Usefulassociative thickeners include those marketed under the Alcogum® tradename (Alco Chemical Company, TN), the Acrysol® trade name (Rohm & Haas,PA), and the Viscalex® trade name (Ciba Specialty Chemicals, NY).

In one illustrative embodiment, the rheological modifier comprises aHEUR and a cellulose ether, e.g., an alkyl hydroxypropyl celluloseether. Without intending to be bound by any particular theory, it isbelieved that the combination of an associative thickener and acellulose ether provides improved application and storage properties.For example, the lubricity and flow characteristic of the joint compoundcompositions (when applied to a substrate) can be improved by using sucha combination of associative thickener and cellulose ether.Additionally, such a combination can help prevent the spheres of thejoint compound compositions from settling out (when the joint compoundcompositions are stored in bulk).

The rheologically modified associative thickener system generallyperforms best under alkaline conditions. Thus, it is generally advisableto include a basic material in the joint compound composition in orderto give the final joint compound composition a pH of at least about 8.0.A variety of basic materials may be used to increase the pH includingbut not limited to ammonia, caustic soda (sodium hydroxide),tri-ethylamine (TEA), and 2-amino-2-methyl-1 propanol (AMP). In variousembodiments, the joint compound composition comprises about 0.001 wt. %to about 10 wt. %, about 0.01 wt. % to about 0.5 wt. %, and/or about0.01 wt. % to about 0.50 wt. % of the alkaline/basic material.

In some embodiments, joint compound composition optionally comprisesbiocide in any suitable amount, e.g., from about 0% to about 3% byweight of the wet composition, such as from about 0.05% to about 2%,from about 0.1% to about 1.5%, or from about 0.1% to about 1%. Ifincluded, in some embodiments of joint compound composition, the biocidecomprises a bactericide and/or a fungicide. An illustrative usefulbactericide is marketed under the MERGAL 174® trade name (TROY ChemicalCorporation). An illustrative useful fungicide is marketed under theFUNGITROL® trade name (International Specialty Products, New Jersey), orany combination thereof.

The joint compound composition can be formulated to have any suitableviscosity to allow for workability as will be understood in the art. Forexample, the viscosity of the joint compound composition when wet canhave a viscosity from about 100 Brabender units (BU) to about 700 BU,such as from about 100 BU to about 600 BU, about 100 BU to about 500 BU,about 100 BU to about 400 BU, about 100 BU to about 300 BU, about 100 BUto about 200 BU, about 130 BU to about 700 BU, about 130 BU to about 600BU, about 130 BU to about 500 BU, about 130 BU to about 400 BU, about130 BU to about 300 BU, about 130 BU to about 200 BU, about 150 BU toabout 700 BU, about 150 BU to about 600 BU, about 150 BU to about 500BU, about 150 BU to about 400 BU, about 150 BU to about 300 BU, or about150 BU to about 200 BU. One of ordinary skill in the art will readilyrecognize Brabender units. The viscosity is measured according to ASTMC474-05, Section 5 using a CW Brabender viscometer with a Type-A Pin,sample cup size of ½ pint with a 250 cm-gm cartridge BrabenderTorque-Head and an RPM of 75.

Desirably, in some embodiments, to enhance the anti-shrinkage propertyof the joint compound composition, water content is desirably reducedcompared with conventional formulations. It will be understood that someraw materials (e.g., latex emulsions and the like) are provided in anaqueous form. However, additional water (e.g., gauging water) isdesirably kept low in some embodiments, e.g., in an amount of about 60%or less by weight of the wet composition, e.g., from about 0% to about50%, such from about 0% to about 30%, from about 0% to about 15%, orfrom about 0% to about 10%, etc. In some embodiments, the total watercontent of the joint compound, including water from other raw materialincluding latex emulsion binder, and any gauging water, could range,e.g., from about 5% to about 60% by weight of the wet composition, suchas from about 10% to about 45% by weight, or from about 25% to about 45%by weight, or over.

In some embodiments, the invention provides a joint compound compositionconsisting essentially of (a) latex emulsion binder in an amount fromabout 3% to about 90% by weight of the wet composition; (b) a pluralityof hollow spheres having an average isostatic crush strength of at leastabout 100 psi, as measured according to ASTM D3102-78, wherein thespheres are present in an amount from about 5% to about 25% by weight ofthe wet composition; (c) nonionic surfactant in an amount from about0.001% to about 5% by weight of the wet composition; and (d) humectantin an amount from about 0.001% to about 3% by weight of the wetcomposition; and, optionally, (e) defoamer in an amount from about 0.05%to about 5% by weight of the wet composition; (f) rheological modifierin an amount from about 0.1% to about 5% by weight of the wetcomposition; (g) biocide, in an amount from about 0.1% to about 1.5% byweight of the wet composition; (h) bulk filler, such as calciumcarbonate or limestone in an amount from about 1% to about 40% by weightof the wet composition; and (i) delaminated clay, such as kaolin clay,in an amount from about 0.1% to about 5% by weight of the wetcomposition. In such embodiments, the composition precludes any rawmaterial other than the aforesaid ingredients that materially affectsthe inventive joint compound composition.

Embodiments of the invention also provide a wall assembly in accordancewith the various aspects described herein. The wall assembly comprisestwo adjacent boards, joined by a seam. In some embodiments, onlyone-coat of the joint compound is applied over the seam to provide auniform aesthetic appearance. However, if desired, more than one coat(e.g., two or three coats) may be applied depending on the level offinish desired. The joint compound composition comprises binder selectedfrom acrylic acid polymers, acrylic acid copolymers, alkyds,polyurethanes, polyesters, epoxies, and combinations thereof. Thecomposition also comprises a plurality of hollow spheres. The spheresdesirably have an average isostatic crush strength of at least about 100psi as measured according to ASTM D3102-78. The wall assembly furthercomprises dimensionally stable, non-swelling flat joint tape embedded inthe seam.

Embodiments of the invention also provide a method of treating awallboard assembly of two adjacent boards joined by a seam in accordancewith the various aspects described herein. In some embodiments, themethod comprises applying joint tape and one coat of the joint compoundcomposition to the seam. The joint compound composition comprises binderselected from acrylic acid polymers, acrylic acid copolymers, alkyds,polyurethanes, polyesters, epoxies, and combinations thereof. Thecomposition also comprises a plurality of hollow spheres. The spheresdesirably have an average isostatic crush strength of at least about 100psi as measured according to ASTM D3102-78. The method further comprisesdrying the composition. In some embodiments, after the joint compound isapplied and dried, the wallboard assembly can be sanded and/or paintedto give a desired visual appearance.

The following embodiments further illustrate aspects of the inventionbut, of course, should not be construed as in any way limiting itsscope.

In an embodiment, a drying-type joint compound composition comprises, abinder selected from acrylic acid polymers, acrylic acid copolymers,alkyds, polyurethanes, polyesters, epoxies, and combinations thereof;and a plurality of hollow spheres, wherein the spheres have an averageisostatic crush strength of at least about 100 psi as measured accordingto ASTM D3102-78.

In another embodiment of the joint compound composition, the binder isan acrylic acid polymer or acrylic acid copolymer.

In another embodiment of the joint compound composition, the binder isin the form of an aqueous emulsion.

In another embodiment of the joint compound composition, the compositionhas a density from about 2 lb/gal to about 8 lb/gal.

In another embodiment of the joint compound composition, the compositionexhibits a shrinkage of about 2% or less as measured by ASTM C474-05.

In another embodiment of the joint compound composition, the compositionis substantially free of setting minerals, bulk filler, clays, starch,mica, or a combination thereof.

In another embodiment of the joint compound composition, the compositionis substantially free of calcium carbonate, expanded perlite, calciummagnesium carbonate, limestone, calcium sulfate dihydrate, delaminatedclay, such as kaolin clay, talcs, diatomaceous earth, or a combinationthereof.

In one embodiment of the joint compound composition, the composition issubstantially free of gelling clays. Such gelling clays includeattapulgites, sepiolites, bentonites, laponites, nontronites,beidellites, laponites, yakhontovites, zincsilites, volkonskoites,hectorites, saponites, ferrosaponites, sauconites, swinefordites,pimelites, sobockites, stevensites, svinfordites, vermiculites,water-swellable synthetic clays, smectites, e.g., montmorillonites,particularly sodium montmorillonite, magnesium montmorillonite, andcalcium montmorillonite, illites, mixed layered illite/smectite mineralssuch as rectorites, tarosovites, and ledikites, magnesium aluminumsilicates, and admixtures of the clays named above. Palygorskiteattapulgite clays are one type of illustrative gelling clay that areexcluded in this embodiment.

In another embodiment of the joint compound composition, the binder hasa glass transition temperature (Tg) from about 32° F. to about 70° F.

In another embodiment of the compound composition, the binder has aminimum film forming temperature (MMFT) from about 32° F. to about 90°F.

In another embodiment of the joint compound composition, the sphereshave an isostatic crush strength of at least about 250 psi.

In another embodiment of the joint compound composition, the sphereshave a density from about 0.0015 lb/in³ to about 0.04 lb/in³.

In another embodiment of the joint compound composition, the spherescomprise lime boro-silicate, polystyrene, ceramic, recycled-glass,expanded glass, and lightweight polyolefin beads, thermoplastic,thermoset, or any combination thereof.

In another embodiment of the joint compound composition, the compositionfurther comprises a nonionic surfactant having a hydrophilic-lipophilicbalance (HLB) from about 3 to about 20.

In another embodiment of a joint compound composition consistingessentially of: (a) latex emulsion binder in an amount from about 3% toabout 90% by weight of the wet composition; (b) a plurality of hollowspheres having an average isostatic crush strength of at least about 100psi as measured according to ASTM D3102-78, wherein the spheres arepresent in an amount from about 5% to about 25% by weight of the wetcomposition; (c) nonionic surfactant in an amount from about 0.001% toabout 5% by weight of the wet composition; and (d) humectant in anamount from about 0.001% to about 3% by weight of the wet composition;and, optionally: (e) defoamer in an amount from about 0.05% to about 5%by weight of the wet composition; (f) rheological modifier in an amountfrom about 0.1% to about 5% by weight of the wet composition; (g)biocide, in an amount from about 0.1% to about 1.5% by weight of the wetcomposition; (h) bulk filler, such as calcium carbonate or limestone inan amount from about 1% to about 40% by weight of the wet composition;and (i) delaminated clay, such as kaolin clay, in an amount from about0.1% to about 5% by weight of the wet composition.

In another embodiment, a wall assembly comprises: (a) two adjacentboards, joined by a seam; (b) only one-coat of the joint compoundcomposition of claim 1 in the seam to provide a uniform aestheticappearance; and (c) dimensionally stable non-swelling flat joint tapeembedded in the seam.

In another embodiment of the wall assembly, at least one board has atapered edge adjacent to the seam, the taper edge having a maximum depthof about 0.125 inch (about 0.3 cm) or less.

In another embodiment of the wall assembly, the boards comprisesopposing face and back surfaces, wherein the faces of two adjacentboards are disposed with respect to each other to define an insidecorner with a corner angle between the board faces from about 30° toabout 180°.

In another embodiment of the wall assembly, the boards comprise opposingface and back surfaces, the faces of two adjacent boards are disposedwith respect to each other to define an outside corner with an anglebetween the board faces from about 180° to about 300°.

In another embodiment of the wall assembly, the assembly furthercomprises reinforcement trim disposed over the seam, wherein the trimcomprises (i) a facing material comprising paper having a dimensionalstability of less than about 0.4% machine direction expansion and lessthan about 2.5% cross direction expansion after 30 minute immersion inwater as measured according to ASTM C474-05, Section 12, and (ii) areinforcement backing comprising paper, plastic, natural or syntheticfiber, carbon fiber, polyester, polycarbonate, fiberglass, non-wovennatural or synthetic materials, woven natural or synthetic materials,spun polyolefin, or metal, wherein the backing has a thickness fromabout 0.012 inches (about 0.03 cm) to about 0.0625 inches (about 0.2cm).

In another embodiment of the wall assembly, the assembly comprisesadhesive for at least partially affixing the reinforcement trim to theedges of the board.

In another embodiment of the wall assembly, the assembly furthercomprises at least one framing member and adhesive, wherein the adhesiveat least partially affixes at least one board to the framing member.

In another embodiment presented a method of treating a wallboardassembly of two adjacent boards joined by a seam, the method comprises(a) applying joint tape and one coat of the joint compound compositionof claim 1 to the seam; and (b) drying the composition.

In another embodiment is presented, a reinforcement trim for protectinga seam of two adjacent boards having opposing face and back surfaces,the faces being disposed with respect to each other at an angle betweenthe board faces, the trim comprising: a paper face characterized by anon-swelling synthetic paper facing material; and a reinforcementbacking comprising paper, thermoplastic, thermoset, natural or syntheticfiber, carbon fiber, polyester, polycarbonate, fiberglass, non-wovennatural or synthetic materials, woven natural or synthetic materials,spun polyolefin, or metal, wherein the backing has a thickness fromabout 0.012 inches (about 0.03 cm) to about 0.0625 inches (about 0.2cm).

In another embodiment of the drying-type joint compound compositioncomprises, a binder selected from acrylic acid polymers, acrylic acidcopolymers, alkyds, polyurethanes, polyesters, epoxies, and combinationsthereof; and a plurality of hollow spheres, wherein the spheres have anaverage isostatic crush strength of at least about 250 psi as measuredaccording to ASTM D3102-78; and wherein the density of the spheres arefrom about 0.0015 lb/in³ (about 0.04 g/cm³) to about 0.04 lb/in³ (about1.1 g/cm³).

In another embodiment of the joint compound composition, the sphereshave an isostatic crush strength of at least about 500 psi.

In another embodiment of the joint compound composition, the sphereshave a density from about 0.0018 lb/in³ (≈0.05 g/cm³) to about 0.036lb/in³ (≈1 g/cm³).

In another embodiment of the joint compound composition, in a 3/16 inch(about 0.5 cm) stripe, at least 60% of the water content is removed bydrying within about 1.5 to 4.5 hours in a moderate environment of about75° F. (about 24° C.) and about 50% relative humidity.

In another embodiment of the joint compound composition, in a 3/16 inch(about 0.5 cm) stripe, at least 60% of the water content is removedwithin about 1 to about 3 hours in a hot and dry environment of about95° F. (about 35° C.) and about 10% relative humidity.

In another embodiment of the joint compound composition, in a 3/16 inch(about 0.5 cm) stripe, at least 60% of the water content is removedwithin about 5 to about 12.5 hours in a cold and damp environment ofabout 40° F. (about 4° C.) and about 80% relative humidity.

In another embodiment of the joint compound composition, in a 1/16(about 0.2 cm) inch stripe, at least 60% of the water content is removedby drying within about 0.5 to 2 hours in a moderate environment of about75° F. (about 24° C.) and about 50% relative humidity.

In another embodiment of the joint compound composition, in a 1/16 inch(about 0.2 cm) stripe, at least 60% of the water content is removedwithin about 1 hour in a hot and dry environment of about 95° F. (about35° C.) and about 10% relative humidity.

In another embodiment of the joint compound composition, in a 1/16 inch(about 0.2 cm) stripe, at least 60% of the water content is removedwithin about 0.5 to about 3 hours in a cold and damp environment ofabout 40° F. (about 4° C.) and about 80% relative humidity.

The following examples further illustrate the invention but, of course,should not be construed as in any way limiting its scope.

Example 1

This example sets forth three sample formulations (1A, 1B, and 1C)illustrating joint compound in accordance with embodiments of theinvention.

As an illustrative method of preparation, all of the liquid ingredientswere added to a Hobart Model N50 mixer. In this respect, it is to benoted that the functional filler (Scotchlite K1) and rheological polymer(Cellosize DSC) were the only dry materials with the remainderconsidered to be in liquid form for purposes of addition to the mixer.Since the functional filler was in bulk form and the rheological polymerwas in a small quantity, the rheological polymer was added to thefunctional filler, and the combined dry material was added to the mixerwith the liquids already included. The resulting composition was mixedfor approximately two minutes until uniform.

However, it will be understood that the formulations can be prepared inany suitable manner. For example, the composition can be prepared on aplant scale in horizontal shafted mixer with helical blade configurationor the like to promote suitable mixing dynamics as will be understood byone of ordinary skill in the art.

Formulation 1A is set forth in Table 1 below. It will be understood“added water” refers to additional water not already present in any ofthe ingredients (e.g., RHOPLEX is in the form of a 47/53 solids/wateremulsion by weight).

TABLE 1 Formulation 1A Weight Ingredient Type (lb) Wt. % PolyacrylateEster Emulsion Binder 700 71.6% (RHOPLEX E-330 ™) Rohm & Haas (UK)Petroleum Distillate Defoamer 4 0.4% (Bubreak 4412 ™) BuckmanLaboratories (Memphis, TN) Octylphenol Ethoxylate Surfactant 2 0.2%(TRITON X-405 ™) The Dow Chemical Company (Midland, MI)Soda-Lime-Borosilicate Glass Bubbles Functional 150 15.3% (SCOTCHLITEK1 ™) Filler 3M (St. Paul, MN) 2((Hydroxymethyl)amino)ethanol Biocide 10.1% (MERGAL 174 ™) Troy Chemical Corporation (Florham Park, NJ)Tributyltin Benzoate Biocide 1 0.1% (FUNGITROL 158 ™) InternationalSpecialty Products (Wayne, NJ) Ethylene Glycol Humectant 15 1.5% MEGlobal (Dubai, United Arab Emirates) Hydroxyethyl Cellulose Rheological5 0.5% (Cellosize DSC ™) Polymer The Dow Chemical Company (Midland, MI)Methylacrylate-based Emulsion Rheology 0 0.0% Copolymer (Alcogum L-62 ™)Modifier Akzo Nobel (Amsterdam, Netherlands) Added Water 100 10.2%Totals 978 100.0%

Formulation 1B is set forth in Table 2 below.

TABLE 2 Formulation 1B Weight Ingredient Type (lb) Wt. % PolyacrylateEster Emulsion Binder 900 83.8% (RHOPLEX E-330 ™) Rohm & Haas (UK)Petroleum Distillate Defoamer 0 0.0% (Bubreak 4412 ™) BuckmanLaboratories (Memphis, TN) Octylphenol Ethoxylate Surfactant 2 0.2%(TRITON X-405 ™) The Dow Chemical Company (Midland, MI)Soda-Lime-Borosilicate Glass Bubbles Functional 150 14.0% (SCOTCHLITEK1 ™) Filler 3M (St. Paul, MN) 2((Hydroxymethyl)amino)ethanol Biocide 10.1% (MERGAL 174 ™) Troy Chemical Corporation (Florham Park, NJ)Tributyltin Benzoate Biocide 1 0.1% (FUNGITROL 158™) InternationalSpecialty Products (Wayne, NJ) Ethylene Glycol Humectant 15 1.4% MEGlobal (Dubai, United Arab Emirates) Hydroxyethyl Cellulose Rheological5 0.5% (Cellosize DSC ™) Polymer The Dow Chemical Company (Midland, MI)Methylacrylate-based Emulsion Rheological 0 0.0% Copolymer (AlcogumL-62 ™) Modifier Akzo Nobel (Amsterdam, Netherlands) Added Water 0 0.0%Total 1074 100.0%

Formulation 10 is set forth in Table 3 below.

TABLE 3 Formulation 1C Weight Ingredient Type (lb) Wt. % PolyacrylateEster Emulsion Binder 800 74.3% (RHOPLEX E-330 ™) Rohm & Haas (UK)Petroleum Distillate Defoamer 3 0.3% (Bubreak 4412 ™) BuckmanLaboratories (Memphis, TN) Octylphenol Ethoxylate Surfactant 2 0.2%(TRITON X-405 ™) The Dow Chemical Company (Midland, MI)Soda-Lime-Borosilicate Glass Bubbles Functional 150 13.9% (SCOTCHLITEK1 ™) Filler 3M (St. Paul, MN) 2((Hydroxymethyl)amino)ethanol Biocide 10.1% (MERGAL 174 ™) Troy Chemical Corporation (Florham Park, NJ)Tributyltin Benzoate Biocide 1 0.1% (FUNGITROL 158 ™) InternationalSpecialty Products (Wayne, NJ) Ethylene Glycol Humectant 15 1.4% MEGlobal (Dubai, United Arab Emirates) Hydroxyethyl Cellulose Rheological2 0.2% (Cellosize DSC ™) Polymer The Dow Chemical Company (Midland, MI)Methylacrylate-based Emulsion Rheological 6 0.6% Copolymer (AlcogumL-62 ™) Modifier Akzo Nobel (Amsterdam, Netherlands) Added Water 97 9.0%Total 1077 100.0%

The formulations set forth in Table 1 include relatively low amounts ofwater and result in low shrinkage levels while also exhibiting goodcompressive strength and flexural strength. They can readily be appliedwith fewer coats than applied in conventional systems (e.g., desirablyin a one-coat application system) to seams, trim, and fasteners in wallassemblies in accordance with some embodiments of the invention. As aresult, Formulations 1A-1C permit efficient application withoutconsiderable delays requiring downtime as each separate coat dries. TheFormulations 1A-1C also allow for easy application, requiring less skillon the part of the user, since the formulations can be applied closer tothe plane of wall assemblies. The Formulations 1A-1C exhibited shrinkagefrom about zero to about 3% as measured in accordance with ASTM C474-05,Section 6. In addition, Formulations 1A-1C were crack resistant whenmeasured in accordance with ASTM C474-05, Section 7.

Example 2

This Example illustrates the superior strength properties exhibited byjoint compound in accordance with embodiments of the invention ascompared with two different conventional joint compounds.

A total of three specimens were tested for flexural strength. Each jointcompound specimen was formed and dried into a strip having a length of10 inches, a width of 2 inches (about 5 cm), and a thickness of 0.0625inches (about 0.2 cm). Each specimen was placed on a table with its endsseated on 0.125 (⅛) inch (about 0.3 cm) thick spacers in order todemonstrate that, with the slightest displacement, the brittle natureand friability associated with representative samples of commerciallyavailable joint compound product formulations used in the industry. Adown force of about 200 gm was applied to the center of each jointcompound strip with a metal probe.

For comparative purposes, the first specimen, Formulation 2A, was aconventional joint compound commercially available as SHEETROCK® BrandLightweight All Purpose Joint Compound from USG that has a density ofapproximately 14 lb/gal. The progression of the test is shown in FIGS.19-21. As seen in FIG. 21, the joint compound broke with less than ⅛inch deflection, thereby showing the brittle nature of the specimen.

For further comparative purposes, the second specimen, Formulation 2B,was another conventional joint compound commercially available asSHEETROCK® Brand All Purpose Joint Compound from USG that has a densityof approximately 8 lb/gal. The progression of the test is shown in FIGS.22-24. As seen in FIG. 24, the joint compound broke with less than ⅛inch deflection, thereby showing the brittle nature of the specimen.

The third Formulation, 2C, was prepared in accordance with Formulation1A, as set forth in Table 1, in accordance with embodiments of theinvention Formulation 2C had a density of 3 lb/gal. The progression ofthe test is shown in FIGS. 25-27. As seen in FIG. 27, after ⅛ inchdeflection, the sample did not crack (unlike comparative Formulations 2Aand 2B). Moreover, as seen in FIG. 28, Formulation 2C did not crack orbreak as it was bent even more. In fact, even as Formulation 2C was bentall the way to form a loop, as seen in FIG. 29, the sample did not breakor crack.

It will be understood that Formulation 2C imparted the most desirablefinishing attributes of a drywall joint compound. For example,Formulation 2C did not shrink when dry. In addition, Formulation 2Cremained flexible enough to resist cracking (as opposed to conventionalbrittle compounds shown in Formulations 2A and 2B) yet was sufficientlyrigid to enable easy sanding and smoothing over the surface. Formulation2C could also be easily painted.

Example 3

This example sets forth five sample sets of formulations (2D-F, 3A-C,4A-C, 5A-C, and 6A-C) illustrating a joint compound in accordance withembodiments of the invention.

It will be understood that the formulations can be prepared in anysuitable manner, e.g., as described in Example 1. For example, thecomposition can be prepared on a plant scale in a horizontal shaftedmixer with helical blade configuration or the like to promote suitablemixing dynamics as will be understood by one of ordinary skill in theart.

It will be understood “added water” refers to additional water notalready present in any of the ingredients.

TABLE 4 Formulation 2 D E F Weight Weight Weight Ingredient Type (lb)Wt. % (lb) Wt. % (lb) Wt. % Rhoplex MC-1834P Binder 300.0 46.8 160.026.2 200.0 37.1 Petroleum Distillate Defoamer 2.0 0.3 2.0 0.3 2.0 0.4(Bubreak 4412 ™) Buckman Laboratories (Memphis, TN) OctylphenolEthoxylate Surfactant 0.5 0.1 2.1 0.3 0.5 0.1 (TRITON X-405 ™) The DowChemical Company (Midland, MI) Soda-Lime-Borosilicate Functional 160.025.0 160.0 26.2 160.0 29.7 Glass Bubbles Filler (SCOTCHLITE K1 ™) 3M(St. Paul, MN) 2((Hydroxymethyl)amino)ethanol Biocide 2.0 0.3 2.0 0.32.0 0.4 (MERGAL 174 ™) Troy Chemical Corporation (Florham Park, NJ)Ethylene Glycol ME Humectant 15.0 2.3 15.0 2.5 15.0 2.8 Global (Dubai,United Arab Emirates) Hydroxyethyl Cellulose Rheological 5.0 0.8 3.0 0.53.0 0.6 (Cellosize DSC ™) Polymer The Dow Chemical Company (Midland, MI)Alcogum L-62 Rheological 6.0 0.9 6.0 1.0 6.0 1.1 Modifier Added Water150.0 23.4 260.0 42.6 150.0 27.9 Total 640.5 100.0 610.1 100.0 538.5100.0

TABLE 5 Formulation 3 A B C Weight Weight Weight Ingredient Type (lb)Wt. % (lb) Wt. % (lb) Wt. % Rhoplex MC-1834P Binder 200.0 7.4 300.0 13.9300.0 14.0 Bubreak 4412 Defoamer 4.0 0.1 0.0 0.0 0.0 0.0 Bubreak 4419Defoamer 0.0 0.0 4.0 0.2 4.0 0.2 Scotchlite K1 Functional 100.0 3.7250.0 11.6 400.0 18.7 Filler Scotchlite iM16K Functional 400.0 14.8250.0 11.6 100.0 4.7 Filler Microwhite 100 Filler 1000.0 36.9 500.0 23.2500.0 23.3 Calcium Carbonate Mergal 174 II Biocide 2.0 0.1 2.0 0.1 2.00.1 Ethylene Glycol Humectant 0.0 0.0 0.0 0.0 15.0 0.7 SorbitolHumectant 10.0 0.4 15.0 0.7 0.0 0.0 Actimin Kaolin Clay Rheological 50.01.8 10.0 0.5 1.0 0.0 modifier Cellosize DCS Rheological 10.0 0.4 10.00.5 10.0 0.5 polymer Alcogum L-62 Rheological 0.0 0.0 6.0 0.3 6.0 0.3modifier Minugel FG Rheological 35.0 1.3 6.0 0.3 6.0 0.3 modifier Water900.0 33.2 800.0 37.2 800.0 37.3 Total 2711.0 100.0 2153 100.0 2144.0100.0

TABLE 6 Formulation 4 A B C Weight Weight Weight Ingredient Type (lb)Wt. % (lb) Wt. % (lb) Wt. % Rhoplex MC-1834P Binder 600.0 26.0 900.039.8 300.0 13.2 Bubreak 4419 Defoamer 4.0 0.2 4.0 0.2 4.0 0.2 ScotchliteK1 Functional 100.0 4.3 100.0 4.4 100.0 4.4 Filler Scotchlite iM16KFunctional 400.0 17.3 400.0 17.7 400.0 17.5 Filler Microwhite 100 Filler700.0 30.3 700.0 31.0 700.0 30.7 Calcium Carbonate Mergal 174 II Biocide2.0 0.1 2.0 0.1 2.0 0.1 Sorbitol Humectant 10.0 0.4 10.0 0.4 10.0 0.4Actimin Kaolin Clay Rheological 50.0 2.2 0.0 0.0 20.0 0.9 modifierCellosize DCS Rheological 10.0 0.4 10.0 0.4 10.0 0.4 polymer Minugel FGRheological 35.0 1.5 35.0 1.5 35.0 1.5 modifier Water 400.0 17.3 100.04.4 700.0 30.7 Total 2311.0 100.0 2261 100.0 2281.0 100.0

TABLE 7 Formulation 5 A B C Weight Weight Weight Ingredient Type (lb)Wt. % (lb) Wt. % (lb) Wt. % Rhoplex MC-1834P Binder 600.0 26.3 900.040.4 300.0 13.3 Bubreak 4419 Defoamer 4.0 0.2 4.0 0.2 4.0 0.2 ScotchliteS15 Functional 100.0 4.4 250.0 11.2 400.0 17.8 Filler Scotchlite iM30KFunctional 400.0 17.5 250.0 11.2 100.0 4.4 Filler Microwhite 100 Filler700.0 30.7 700.0 31.4 400.0 17.8 Calcium Carbonate Minex 7 Filler 0.00.0 0.0 0.0 300.0 13.3 Mergal 174 II Biocide 2.0 0.1 2.0 0.1 2.0 0.1Sorbitol Humectant 10.0 0.4 10.0 0.4 10.0 0.4 Actimin Kaolin ClayRheological 50.0 2.2 0.0 0.0 20.0 0.9 modifier Cellosize DCS Rheological10.0 0.4 10.0 0.4 10.0 0.4 polymer Alcogum L-62 Rheological 6.0 0.3 3.00.1 3.0 0.1 modifier Water 400.0 17.5 100.0 4.5 700.0 31.1 Total 2282.0100.0 2229 100.0 2249.0 100.0

TABLE 8 Formulation 6 A B C Weight Weight Weight Ingredient Type (lb)Wt. % (lb) Wt. % (lb) Wt. % Rhoplex MC-1834P Binder 600.0 48.7 900.073.2 300.0 19.6 Bubreak 4419 Defoamer 4.0 0.3 4.0 0.3 4.0 0.3 ScotchliteK1 Functional 100.0 8.1 150.0 12.2 400.0 26.2 Filler Scotchlite iM30KFunctional 400.0 32.5 150.0 12.2 100.0 6.5 Filler Mergal 174 II Biocide2.0 0.2 2.0 0.2 2.0 0.1 Sorbitol Humectant 10.0 0.8 10.0 0.8 10.0 0.7Cellosize DCS Rheological 10.0 0.8 10.0 0.8 10.0 0.7 polymer AlcogumL-62 Rheological 6.0 0.5 3.0 0.2 3.0 0.2 modifier Water 100.0 8.1 0.00.0 700.0 45.8 Total 1232.0 100.0 1229 100.0 1529.0 100.0

Example 4

The Example below Illustrates the superior flexibility, crackresistance, and strength over commercially available joint compoundswhen used in the novel joint system and tested using ASTM C474.

Formulations 1A and 2E, as described above, were prepared. Also, aconventional weight all-purpose joint compound (Formulation AP) and alightweight all purpose joint compound (Formulation LW) were used forcomparative purposes. Formulation AP was SHEETROCK® Brand All-PurposeJoint Compound, and Formulation LW was SHEETROCK® Brand Lightweight AllPurpose Joint Compound. Each sample was prepared in triplicate.

Each Formulation was prepared and tested according to the ASTM C474conducted in the following manner. The joint compounds were applied overa gap created at the gypsum board seam with a waxed spacer. A syntheticjoint tape was affixed over the gypsum panel joint. The samples werelayered on top of the tape and conditioned for 24 hours at 70° F. (about21° C.) and 50% relative humidity. The waxed spacers were removed, andthe samples were mounted into test fixtures. The fixture was loaded intothe Universal Test Machine (UTM).

Each joint system was challenged under a load at 0.4 inches/min. (about1 cm/min.) at a constant rate of displacement until the sample failed.The load and the displacement were recorded twice—first when a visualfirst crack was observed, and second when the system failed.

FIGS. 30-34 show the superiority of Formulations 1A and 2E tocomparative Formulations AP and LW under the testing conditions.

FIG. 30 is a box plot chart displaying the tension displacement when thefirst crack was observed and was measured in inches along the Y-axis,and various joint compounds, along the X-axis, specifically Formulations1A and 2E, in accordance with embodiments of the invention andFormulations AP and LW as comparative examples. The chart illustratesthat Formulations 1A and 2E were displaced about 0.12 inches (about 0.3cm) before the observation of the first crack. On the other hand, thefirst crack was observed in Formulation AP at 0.06 inch (about 0.15 cm)and the first crack was observed in Formulation LW at 0.08 inch (about0.2 cm). It is worth noting that the Formulations 1A and 2E did notvisibly crack due to the displacement. They demonstrated cracks onlyafter the underlying joint tape failed and gave way. Thus, Formulations1A and 2E demonstrated a significantly higher crack resistance comparedto the commercially available compounds, Formulations AP and LW.

FIG. 31 is a box plot chart displaying the load (lbs) when the firstcrack was observed, measured in pounds (lbs), along the Y-axis, andvarious joint compounds, along the X-axis, specifically Formulations 1Aand 2E, in accordance with embodiments of the invention and FormulationsAP and LW as comparative examples. The chart illustrates thatFormulations 1A and 2E could bear 124 lb (about 56 kg) and 95 lb (about43 lb), respectively when the first crack appeared. On the other hand,first crack in Formulation AP was observed when the load was 53 lb(about 24 kg) and first crack in Formulation LW was observed when theload was 60 lb (about 27 kg). It is worth noting that the Formulations1A and 2E did not visibly crack due to the displacement. Theydemonstrated cracks only after the underlying joint tape failed and gaveway. Thus, Formulations 1A and 2E demonstrated a significantly highercrack resistance and could bear significantly higher loads beforefailure compared to the commercially available compounds Formulations APand LW.

FIG. 32 is a box plot chart displaying the shear displacement in incheswhen the first crack was observed, measured in inches, along the Y-axis,and various joint compounds, along the X-axis, specifically Formulations1A and 2E, in accordance with embodiments of the invention andFormulations AP and LW as comparative examples. The chart illustratesthat Formulations 1A and 2E were displaced about 0.11 and 0.12 inches(about 0.3 cm), respectively, before the observation of the first crack.On the other hand, the first crack was observed in Formulation AP at0.08 inch (about 0.2 cm) and the first crack was observed in FormulationLW at 0.11 inch (about 0.3 cm). It is worth noting that the Formulations1A and 2E did not visibly crack due to the displacement. Theydemonstrated cracks only after the underlying joint tape failed and gaveway. Thus, a large variation in the range of the data is observed forFormulations 1A and 2E. However, Formulations AP and LW visiblycracked/fractured well before the joint tape and seam failed. Thus,Formulations 1A and 2E demonstrated a significantly higher shear crackresistance compared to the commercially available compounds FormulationsAP and LW.

FIG. 33 is a box plot chart displaying the shear peak displacement whenthe first crack was observed, measured in inches, along the Y-axis, andvarious joint compounds along the X-axis, specifically Formulations 1Aand 2E in accordance with embodiments of the invention and FormulationsAP and LW as comparative examples. The chart illustrates that the peakshear displacement for Formulations 1A and 2E was 0.23 inches (about 0.6cm) and 0.25 inches (about 0.6 cm), respectively, before the observationof the first crack. On the other hand, the first crack was observed inFormulation AP after a peak shear displacement of 0.1 inch (about 0.25cm) and the first crack was observed in Formulation LW at a shear peakdisplacement of at 0.13 inch (about 0.3 cm). It is worth noting that theFormulations 1A and 2E did not visibly crack due to the displacement.They demonstrated cracks only after the underlying joint tape failed andgave way. Thus, Formulations 1A and 2E demonstrated a significantlyhigher peak shear displacement compared to the commercially availablecompounds Formulations AP and LW.

FIG. 34 is a box plot chart displaying the shear displacement ratio(i.e., a ratio of peak displacement at joint system failure todisplacement at first crack) along the Y-axis, and various jointcompounds along the X-axis, specifically Formulations 1A and 2E inaccordance with embodiments of the invention and Formulations AP and LWas comparative examples. The chart illustrates that Formulations 1A and2E had a shear displacement ratio of about 2.3 before the observation ofthe first crack but Formulation AP had a shear displacement ratio ofabout 1.3, and Formulation LW had a shear displacement ratio of 1.2.Thus, Formulations 1A and 2E demonstrated greater elongation and stretchproperties even after the observation of the first crack until theyreached complete failure by tearing in the joint system. It is worthnoting that the Formulations 1A and 2E did not visibly crack due to thedisplacement. They demonstrated cracks only after the underlying jointtape failed and gave way. On the other hand, Formulation AP and LWcompounds are brittle material and demonstrated peak displacementshortly after the first crack was visible.

The results of this Example illustrate that when the joint system wasplaced into tension, Formulations 1A and 2E both demonstrated a superiorelongation and physical displacement before failure while FormulationsAP and LW were brittle and did not impart similar performance under thesame testing condition of the joint system of the present invention.Also, these commercially available joint compounds did not perform anybetter in the conventional joint systems.

When the joint system of the present invention was challenged undershear forces, the differences between the joint compounds of the presentinvention and conventional joint compounds became even more apparent.The joint compounds of this example exhibited high superiordisplacements and higher displacement ratios than the commerciallyavailable joint compounds. Thus, the joint compounds of the presentinvention demonstrated a high strength and crack resistance.

Example 5

This Example illustrates the superior flexibility and elastomericproperties or flexibility/degree of embrittlement when used in the noveljoint system and tested using ASTM C711.

Each Formulation was prepared and tested according to the ASTM C711conducted in the following manner. Samples of Formulations 1A and 2Ewere prepared, and representative commercially available joint compoundsFormulation AP-SHEETROCK® Brand All-Purpose Joint Compound andFormulation LW-SHEETROCK® Brand Lightweight All Purpose Joint Compoundwere used for comparative purposes. Each sample was prepared intriplicate.

A ⅛-inch (about 0.3 cm) thick strip of joint compound (2″×10″) (about 5cm×about 25 cm) was laid over a bond breaker film, i.e., the jointcompound does not adhere to film after drying. The samples were preparedin triplicate for each environmental condition. The samples were thendried under four different environmental test conditions for 24 hours. Asecond set of tests was conducted after conditioning for 28 days. Thesamples were removed from the bond breaker film and were subjected to abending condition around a 1 inch (about 2.5 cm) diameter cylindricalmandrel to assess elastomeric and flexibility properties of the jointcompounds. The samples were then visually graded on a 3 rating scale todetermine the degree of elastomeric flexibility properties illustratedby ASTM C711.

It is to be noted that ASTM C711 published 2009 illustrates withphotographs the differences between a satisfactory joint compound andunsatisfactory joint compounds when mounted and bent around a mandrel inaccordance with the test. One provides a depiction of a satisfactoryjoint compound that would receive the pass rating due to a lack ofcracking or any visible failure. Another depicts an unsatisfactory jointcompound that would receive the Fail-A rating due to severe cracking. Athird shows an unsatisfactory joint compound that would receive theFail-B rating due to complete cracking and adhesive failure.

TABLE 9 FLEXIBILITY RESULTS - ASTM C711 24 Hours Environment 1A 2E AP LW40° F./80% relative humidity Pass Pass Fail-B Fail-B Cold/Humid 75°F.-50% relative humidity Pass Pass Fail-B Fail-B Standard/Occupancy 95°F./10% relative humidity Pass Pass Fail-B Fail-B Hot/Dry 90° F./90%relative humidity Pass Pass Fail-B Fail-B Hot/Humid

TABLE 10 FLEXIBILITY RESULTS - ASTM C711 28 Days Environment 1A 2E AP LW40° F./80% relative humidity Pass Pass Fail-B Fail-B Cold/Humid 75°F.-50% relative humidity Pass Pass Fail-B Fail-B Standard/Occupancy 95°F./10% relative humidity Pass Pass Fail-B Fail-B Hot/Dry 90° F./90%relative humidity Pass Pass Fail-B Fail-B Hot/Humid

Table 9 demonstrates the results of the visual test after conditioningthe samples in four different conditions of ASTM C711 for 24 hours. Thespecimens Formulations 1A and 2E performed significantly better than theconventional joint compounds represented by Formulations AP and LW.While Formulations 1A and 2E received a pass rating on each of thestandard condition tests, Formulations AP and LW received a Fail-Brating.

Table 10 demonstrates the results of the visual test after conditioningthe samples in four different conditions of ASTM C711 for 28 days. Thespecimens Formulations 1A and 2E performed significantly better than theconventional joint compounds represented by Formulations AP and LW.While Formulations 1A and 2E received a pass rating on each of thestandard condition tests, Formulations AP and LW received a Fail-Brating.

The conventional joint compounds were so brittle under these testingconditions that they failed when even bent less than ⅛-inch deflectionand could not be bent around cylindrical mandrel without catastrophicfailure. The performance of the joint compound under these testconditions helps ensure the structural adequacy and service life of thejoint compounds.

Example 6

This Example Illustrates the superior properties of the joint compoundsand joint system under the real world conditions that are representativeof those encountered in service. The performance criteria based on datafrom these tests ensure structural adequacy of the joint compound andjoint systems during their service life.

The joint system of the present invention and conventional joint systemwere tested using modified ASTM E72 in the following manner. The wallassembly joint system of the present invention was prepared usingFormulations 1A and 2E compounds and compared against Formulations APand LW. Samples of Formulations 1A and 2E were prepared, andrepresentative commercially available joint compounds FormulationAP-SHEETROCK® Brand All-Purpose Joint Compound and FormulationLW-SHEETROCK® Brand Lightweight All Purpose Joint Compound were used forcomparative purposes. Formulation AP represents a conventional weightall-purpose joint compound. Formulation LW represents a lightweight allpurpose joint compound.

Formulations 1A and 2E were used to prepare a test under the Flat JointTreatment (square edge/butt and tapered edge joints). In this system,the joint seams were taped using the synthetic joint reinforcement tapeto affix the joint boards with an adhesive. A single coat of Formulation1A or 2E was applied over the taped joint seams. The fasteners wereprepared by applying one coat of the present invention joint compoundFormulation 1A or 2E over the fasteners.

For comparison, the conventional joint systems are generally prepared bytaping the all flat joint seams using paper joint reinforcement tapeaffixed to joint board with Formulation AP or LW joint compound. Three(3) separate coats of Formulation AP or LW joint compound were appliedover the taped joint seams. The fasteners were prepared by three (3)separate coats of Formulation AP or LW joint compound applied over thefasteners.

FIG. 35A-35C illustrate a modified ASTM E72 racking assembly system totest the wall strength in building construction.

FIG. 35A illustrates a modified ASTM E72 racking assembly system with an8′×8′ (about 2.4 m×about 2.4 m) assembly prepared from 2″×4″ wood studs(about 5 cm×about 10 cm). The wood studs are not shown. The assemblyconsists of two 48″×64″ (about 1.2 m×about 1.6 m) and two 48″×16″ (about1.2 m×about 0.4 m) boards in a staggered configuration. Two main seamsare shown with the dotted lines—a horizontal joint at the mid heightlevel (about 4′ or about 1.2 m) and two vertical joints located at theseam of the two boards.

FIG. 35B illustrates the modified ASTM E72 racking assembly system ofFIG. 35A configured with the 2″×4″ wood studs placed 16 inches (about0.4 m) apart. It also illustrates the two seams—a horizontal joint atthe mid height level (about 4′ or about 1.2 m) and two vertical seamslocated at the joint of the two boards butted against the wooden studs.

FIG. 35C illustrates the modified ASTM E72 racking assembly system ofFIG. 35B, where the bottom was rigidly fixed to the structure, and aforce was applied at the top left corner by a hydraulic ram programmedto run a sinusoidal waveform with varying amplitudes.

During this test, plane of the board in these racking assembly systemswas permitted to move only in the same plane as the face of the wall.The computer controlled hydraulic ram was programmed to run a sinusoidalwaveform with amplitude of 0.025″ (about 0.06 cm) at a frequency 0.5 Hz(2 seconds per cycle) for a cycle count of 500 and hammer the upper lefthand corner of the assembly. After the completion of this cycle, theamplitude was increased to 0.050″ (about 0.12 cm) for a cycle count of500 cycles. After the second cycle was completed, again the amplitudewas increased to 0.075″ (about 0.18 cm) for a cycle count of 500 cycles.This was repeated until the amplitude reached 0.400″ (about 1 cm).During this rigorous testing, the assembly was monitored continuously,and when a failure was observed, the cycle count was noted along withthe location of the failure.

The results show a significant advantage of the elastic membrane effectof Formulations 1A and 2E. Even in areas where the fasteners had failedin the wall assembly, the joint compounds had not been breached orpunctured. Whereas in the comparative conventional system prepared byconventional joint compounds, e.g., Formulations AP and LW, a brittlefractured effect was observed including loss of bond over the fasteners.

Example 7

This Example illustrates the superior drying properties of the jointsystem of the present invention.

As discussed in the specification, the existing joint compounds requirethree separate coats to be applied to fasteners as well as multiplecoats applied to flat seams between boards in the same plane. Each coatmust separately dry before applying a new coat. While, the existing coatdoes not need to dry completely, it is found that about 75% of the watercontent must evaporate from the compound before the coat becomes firmenough to receive a second layer. This creates a significant period ofdowntime during which the other construction trades ordinarily cannotwork inside the building while the wall finishing occurs.

On the other hand, the joint compounds of the present invention onlyrequire a single coat over the seam to provide a uniform aestheticappearance. In case a second layer is required to account for imperfectworkmanship and the like, the joint compounds of the present inventionbecome firm enough to receive the second coat when about 60% of thewater evaporates from the compound.

Samples of Formulations 1A, 2E, 3A, and 4B were prepared. Also aconventional weight all-purpose joint compound (Formulation AP) as wellas a lightweight all purpose joint compound (Formulation LW) were usedfor comparative purposes. Formulation AP was SHEETROCK® BrandAll-Purpose Joint Compound, and Formulation LW was SHEETROCK® BrandLightweight All Purpose Joint Compound.

FIGS. 36A to 36C show the drying profile of the joint compounds of thepresent invention compared with the conventional joint compounds for athick coat, i.e., about 3/16 inches (about 0.5 cm), in which the percentof water evaporated (Y-axis) was plotted against the incremental dryingtimes represented along the X-axis). FIG. 36A shows the drying profilesin a moderate environment, e.g., 75° F. and 50% relative humidity. FIG.36B shows the drying profiles in a hot and dry environment, e.g., 95° F.and 10% relative humidity. FIG. 36C shows the drying profiles in a coldand humid environment, e.g., 40° F. and 80% relative humidity.

A thick coat ( 3/16 inch; about 0.5 cm) is representative of variousapplications, e.g., 1st or 2nd coat over corner reinforcement trim; 1stor 2nd coat over panel/wall offsets; 1st or 2nd coat over square edgebutt joints; and 2nd fill coat over tapered edge joints.

As seen in FIG. 36A, 3/16 inch (about 0.5 cm) coats of Formulations 1A,2E, 3A, and 4B illustrate similar drying profiles at moderateenvironment. In case a second coat is necessary, the first coats ofFormulations 1A, 2E, 3A, and 4B were ready within 1.5 to 4.5 hours. Onthe other hand, the thick coat of Formulation LW was ready to receive asecond coat at about 13 to 15 hours, while the thick coat of FormulationAP was not ready even after 24 hours.

As seen in FIG. 36B, 3/16 inch (about 0.5 cm) coats of Formulations 1A,2E, 3A, and 4B illustrate similar drying profiles at hot-dryenvironment. In case a second coat is necessary, the first coats ofFormulations 1A, 2E, 3A, and 4B were ready within 1 to 3 hours. On theother hand, the thick coats of Formulations LW and AP were ready toreceive a second coat at about 4 to 5.5 hours.

As seen in FIG. 36C, 3/16 inch (about 0.5 cm) coats of Formulations 2Eand 4B demonstrated the fastest drying times in a cold-humid environmentfollowed by Formulations 1A and 3A. In case a second coat is necessary,the first coats of Formulations 1A, 2E, 3A, and 4B were ready within 5to 12.5 hours. On the other hand, the thick coats of Formulations LW andAP were not ready to receive a second coat even after 24 hours.

FIGS. 37A to 37C show the drying profiles of the joint compounds of thepresent invention compared with the conventional joint compounds for athin coat, i.e., about 1/16 inches (about 0.2 cm), in which the percentof water evaporated (Y-axis) was plotted against the incremental dryingtimes represented along the X-axis). FIG. 37A shows the drying profilesin a moderate environment, e.g., 75° F. and 50% relative humidity. FIG.37B shows the drying profiles in a hot and dry environment, e.g., 95° F.and 10% relative humidity. FIG. 37C shows the drying profiles in a coldand humid environment, e.g., 40° F. and 80% relative humidity.

A thin coat ( 1/16 inch; about 0.2 cm) is representative of variousapplications, e.g., 1st or 2nd coat over inside corner finishing; 1st,2nd, or 3rd finishing coat over flat joints; 3rd coat over square edgebutt joints; and 1st, 2nd, or 3rd coat over fasteners.

As seen in FIG. 37A, 1/16 inch (about 0.2 cm) coats of Formulations 1A,2E, 3A, and 4B illustrate similar drying profiles at moderateenvironment. In case a second coat is necessary, the first coats ofFormulations 1A, 2E, 3A, and 4B were ready within 0.5 to less than 2hours. On the other hand, the thin coats of Formulations LW and AP wereready to receive a second coat at about 3.5 to 10 hours.

As seen in FIG. 37B, 1/16 inch (about 0.2 cm) coats of Formulations 1A,2E, 3A, and 4B illustrate similar drying profiles at hot-dryenvironment. In case a second coat is necessary, the first coats ofFormulations 1A, 2E, 3A, and 4B were ready within 1 hour. On the otherhand, the thin coats of Formulations LW and AP were ready to receive asecond coat at about 1.5 to over 2 hours.

As seen in FIG. 37C, 1/16 inch (about 0.2 cm) coats of Formulations 1A,2E, 3A, and 4B illustrate similar drying times in a cold-humidenvironment. In case a second coat is necessary, the first coats ofFormulations 1A, 2E, 3A, and 4B were ready within 0.5 to less than 3hours. On the other hand, the thin coats of Formulations LW and AP wereready to receive a second only after 7 to more than 10 hours.

Thus, this Example shows that the joint compounds of the presentinvention had a faster drying profile in each of the different testenvironment than the conventional joint compound.

The use of the terms “a” and “an” and “the” and “at least one” andsimilar referents in the context of describing the invention (especiallyin the context of the following claims) are to be construed to coverboth the singular and the plural unless otherwise indicated herein orclearly contradicted by context. The use of the term “at least one”followed by a list of one or more items (for example, “at least one of Aand B”) is to be construed to mean one item selected from the listeditems (A or B) or any combination of two or more of the listed items (Aand B) unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

The invention claimed is:
 1. A drying-type joint compound compositioncomprising: (a) binder selected from acrylic acid polymers, acrylic acidcopolymers, alkyds, polyurethanes, polyesters, epoxies, and combinationsthereof; and (b) a plurality of hollow spheres, wherein the spheres havean average isostatic crush strength of at least about 250 psi asmeasured according to ASTM D3102-78; and where the density of thespheres are from about 0.0015 lb/in³ (about 0.04 g/cm³) to about 0.04lb/in³ (about 1.1 g/cm³).
 2. The joint compound composition of claim 1,wherein the binder is an acrylic acid polymer or acrylic acid copolymer.3. The joint compound composition of claim 1, wherein the binder is inthe form of an aqueous emulsion.
 4. The joint compound composition ofclaim 1, wherein the composition has a density from about 2 lb/gal toabout 8 lb/gal.
 5. The joint compound composition of claim 1, whereinthe composition exhibits a shrinkage of about 2% or less, as measured byASTM C474-05.
 6. The joint compound composition of claim 1, wherein thecomposition is substantially free of setting minerals, bulk filler,clays, starch, mica, or a combination thereof.
 7. The joint compoundcomposition of claim 1, wherein the composition is substantially free ofcalcium carbonate, expanded perlite, calcium magnesium carbonate,limestone, calcium sulfate dihydrate, attapulgite clay, kaolin clay,talcs, diatomaceous earth, or a combination thereof.
 8. The jointcompound composition of claim 1, wherein the binder has a glasstransition temperature (Tg) from about 32° F. to about 70° F.
 9. Thejoint compound composition of claim 1, wherein the binder has a minimumfilm forming temperature (MMFT) from about 32° F. to about 90° F. 10.The joint compound composition of claim 1, wherein the spheres have anisostatic crush strength of at least about 500 psi.
 11. The jointcompound composition of claim 1, wherein the spheres have a density fromabout 0.0018 lb/in³ (≈0.05 g/cm³) to about 0.036 lb/in³ (≈1 g/cm³). 12.The joint compound composition of claim 1, wherein the spheres compriselime boro-silicate, polystyrene, ceramic, recycled-glass, expandedglass, and lightweight polyolefin beads, thermoplastic, thermoset, orany combination thereof.
 13. The joint compound composition of claim 1,further comprising a nonionic surfactant having a hydrophilic-lipophilicbalance (HLB) from about 3 to about
 20. 14. A wall assembly comprising:(a) two adjacent boards, joined by a seam; (b) only one-coat of thejoint compound composition of claim 1 in the seam to provide a uniformaesthetic appearance; and (c) dimensionally stable non-swelling flatjoint tape embedded in the seam.